Clutch, Servicing

5 Speed Manual 02J

Clutch, Servicing

Special tools






- 3190 A Mandrel






- 3067 Counter-hold tool

Note:

- Replace clutch plates and pressure plates that have damaged or loose rivets.
- Select the correct clutch plate and pressure plate according to parts list and engine code.






1. Flywheel

- Ensure centering pins are a tight fit
- Contact surface for clutch lining must be free of grooves, oil and grease

2. Clutch plate

- Installation position on two-part flywheel: Shorter hub end (arrow) points toward pressure plate
- Installation position with single piece flywheel: spring cage faces pressure plate
- Centering refer to Fig. 1
- Lightly grease splines

Note:

- Clean input shaft splines and on used clutch plates the hub splines, remove corrosion and apply only a very thin coating of grease, Part No: G 000 100 to input shaft splines. Then move clutch plate back and forth on input shaft until hub moves freely on shaft. Remove excess grease.

3. Pressure plate

- Removing and installing see Fig.1
- Check ends of diaphragm spring see Fig.2

Note:

- Pressure plates are protected against corrosion and greased. Only the contact surface may be cleaned, otherwise the service life of the clutch will be considerably reduced.

4. Bolt

- On two-part flywheel: 13 Nm (10 ft. lbs.)
- On single piece flywheel: 20 Nm (15 ft. lbs.)
- Loosen and tighten gradually and diagonally

Fig. 1 Centering clutch plate / removing and installing pressure plate






- Loosen and tighten bolts gradually and diagonally.
- Reverse position of retainer 3067 when removing.

Note:

- Pressure plate contact surface and clutch plate must make full contact with flywheel. Tighten bolts diagonally and evenly to prevent damage to the centering holes in the pressure plate housing and the centering pins in the flywheel.

Fig. 2 Checking ends of diaphragm spring






- Wear up to half the thickness of the diaphragm spring is permitted.