Attention: Remember that the dust generated 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.
Removing
1. To release access to the clutch assembly, you must first remove the gearbox (see Part B).
Note: If the engine has not been removed from the car, it is recommended to additionally support it with a jack or install special stands under it.
If you plan to reuse the same clutch basket, mark its position on the flywheel (without factory marks).
2. Install special tool KM-6263 (see resist. illustration), hand-tighten the mounting and adjustment bolts. Be careful - the lower mounting bolts of the fixture must be attached to the engine block, and in no case to the oil pan of the crankcase.
6.2. Installing the KM-6263 fixture (4) to remove the clutch: 1, 3, 6. Mounting bolts; 2, 5 Adjusting bolts
3. To center the clutch on the manual transmission F13 and F17 of all modifications, the nozzle KM-6263-21 is used, and on the manual gearbox F23 the nozzle KM-6263-20 is used. Insert centering rod (see resist. illustration) with an appropriate nozzle through the shaft hole with a forcing mandrel into the central journal of the engine crankshaft, center tool KM-6263 and tighten the bolts using a tool.
6.3 Fitting the centering rod (4) (the illustration shows the clutch of another Opel model): 1. Fixture adjusting bolt; 2. Centering rod assembly with nozzle; 3. Fixing nut; 4. Stock; 5. Rod nozzle; 6. Shaft with forcing mandrel
4. Screw in (clockwise) shaft with a squeezing mandrel until the latter comes into contact with the working edges of the petals of the diaphragm spring. Continue to screw in the shaft until it stops - the mandrel will compress the spring and separate the clutch discs.
5. Block the flywheel from turning (see Chapter 2, Section 5), unscrew in a diagonal order 6 bolts securing the clutch to the engine flywheel.
6. Gently turning (counterclock-wise) shaft with forcing mandrel, fully release the diaphragm spring. While holding the basket, remove the centering rod and remove the clutch assembly - if necessary, use the help of an assistant.
7. At the end of the procedure, remove the KM-6263 tool from the engine block.
Examination
8. Most often, the malfunction of the clutch is associated with the wear of the friction linings of the driven disk. However, you should carefully examine the status of all other assembly components.
9. Examine the working surface of the flywheel for cracks, signs of overheating, grooves and other damage - if necessary, replace the flywheel (see chapter 2). Also check the condition and evaluate the flatness of the mating surface of the clutch pressure plate (see resist. illustration).
6.9. Measuring the flatness of the mating surface of the clutch pressure plate
10. 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 torsion springs / dampers for cracks, signs of deformation and other mechanical damage (see resist. illustration). 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.
6.10. 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 along the splines of the gearbox input shaft; 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
11. In tandem with the driven disk, it is also desirable to replace the release bearing (see Section 3). 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 3).
12. Evaluate the condition of the machined surfaces and petals of the pressure plate diaphragm spring (see resist. illustrations). If defects are found, replace the basket assembly. Light polishing marks can be removed with fine sandpaper. Through Opel branded service stations, you can always purchase a remanufactured clutch assembly on an exchange basis.
6.12a. Examples of Diaphragm Spring Wear
6.12b. The friction surface of the pressure plate should be checked for cracks, grooves, deep scratches and signs of overheating
Installation
13. Make sure that the mating surfaces of the flywheel and clutch discs are absolutely clean and dry; if necessary, wipe the working surfaces with a solvent.
14. Install the friction disc with the protruding part of the hub away from the flywheel. Usually, a factory marking is applied to the disc, indicating which side to the flywheel it should be installed.
15. Install the clutch basket - if an old basket is installed, make sure that the landing marks applied during the dismantling process are aligned correctly. Screw in the basket mounting bolts and tighten them only by hand so far in order to ensure the possibility of unhindered centering of the driven disk.
16. Install the KM-6263 tool, insert the centering rod.
Note: Alignment is necessary so that when installing the gearbox, its input shaft passes through the splines in the disc and enters the guide sleeve in the crankshaft trunnion.
17. Using the squeezing mandrel, completely unload the clutch discs (see above) and in several stages diagonally evenly tighten the basket fastening bolts to the required torque. Remove the centering rod and remove the tool.
18. Reinstall the gearbox.
Visitor comments