Remember that the dust produced during the wear of the friction linings of the clutch disc may contain asbestos, which is harmful to health. Do not blow off dust with compressed air and try not to inhale it. Do not use petroleum-based solvents to clean clutch components, use only special brake cleaners or pure methanol. Store used rags in a sealed container.
1. Most often, a malfunction in the functioning of the clutch turns out to be associated with wear of the friction linings of the driven disk. However, you should carefully examine the status of all other assembly components.
2. Examine the working surface of the flywheel for cracks, traces of overheating, grooves and other damage. Minor defects can be eliminated by turning in the conditions of a car service workshop (the groove is recommended to be made regardless of the state of the surface). A description of the procedures for removing and installing the flywheel is given in Section Removal, condition check and installation of a flywheel/drive disk. Also check the condition and evaluate the flatness of the mating surface of the clutch pressure plate.
Measuring the flatness of the mating surface of the clutch pressure plate
3. Assess the degree of wear of the friction linings of the clutch driven disk. The surface of the overlays must rise above the heads of the rivets by at least 1.6 mm. Make sure that all rivets are firmly seated, check the torsion springs / dampers for cracks, signs of deformation and other mechanical damage. Lubrication of friction linings most often occurs due to failure of the crankshaft oil seal, violation of the integrity of the oil pan gasket, the sealing element of the slave cylinder assembly or the manual transmission input shaft oil seal - replace the damaged components. As mentioned above, it is reasonable to replace clutch components every time the assembly is dismantled, so pay attention to the slightest errors.
Assembly of the slave disk
1 — friction linings - in the picture worn below the allowable limit
2 — Torsion springs or dampers - should be checked for cracks and signs of deformation
3 — Splined hub - must slide freely on the splines of the input shaft of the gearbox, the splines must not be excessively worn
4 — Rivets - used to fasten friction linings and, if the latter are worn excessively, they begin to leave grooves on the working surface of the flywheel
4. Together with the driven disk, the release bearing is also always replaced. If the driven disk is in order, check the condition of the release bearing - the bearing should rotate smoothly, without signs of jamming. The mating surfaces must be absolutely smooth and undamaged, without cracks, burrs or gouges. If there is no certainty in determining the condition of the bearing, replace the slave cylinder assembly (see Section Removing, checking and installing the clutch release bearing).
5. Estimate a condition of the processed surfaces and petals of a diaphragm spring of a press plate In case of revealing of defects replace assembly of a basket. Light polishing marks can be removed with fine sandpaper. You can always purchase a remanufactured clutch assembly on an exchange basis through Opel branded workshops.
Examples of Diaphragm Spring Wear
Normal leaf wear
Excessive petal wear
Petals broken or bent
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