Contents: Removal ⬇ Installation ⬇
The clutch can be removed with the gearbox and engine installed. A special tool is required for removal. The picture shows the F16 gearbox.
Removal
Place the car on jack stands.
Unscrew the bearing shield cover.
Remove the retaining ring (arrow). Unscrew the cylindrical screw.
Remove the transmission drive shaft using a special tool.
If you don't have a special device for extracting the drive shaft of the gearbox, make a temporary one. To do this, you will need a steel plate measuring 10x10 cm and about 7 mm thick, with an 8 mm hole drilled in the center. Insert a M7x60 screw into the hole and screw it into the drive shaft of the gearbox. Using two crowbars, pry the steel plate from below and remove the shaft.
Install the special device KM-449-1 with the stop 22-1 to extract the gearbox drive shaft. Screw the device KM-449-1 into the shaft and remove the shaft using the stop 22-1.
Unscrew the clutch cover from the gearbox housing.
Use a screwdriver to remove the safety clip from the screw portion of the clutch cable and remove the clutch cable from the release lever.
Press down with a crowbar and snap in place with three KM450 clamps (arrow).
Note: Distribute them around the circumference.
Unscrew the clutch basket from the flywheel and remove it.
Installation
Caution: Before installing the driven disk, check whether the release bearing clutch gasket is dirty. If dirty, replace it.
The clutch assembly together with the installed driven disk is secured to the flywheel with screws.
The markings on the clutch and flywheel must align (arrow).
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The long part of the clutch disc hub should face the gearbox.
Clean and lubricate the clutch splines with general purpose grease.
Slightly lift the clutch disc and align it with the gearbox drive shaft. Carefully, by hand, insert the gearbox drive shaft into the splines of the clutch disc and gear block. In this case, the splines of both spline cuts of the shaft must enter the corresponding spline cuts of the clutch disc and gear block.
Secure the clutch to the flywheel with a torque of 15 Nm.
Screw the cylindrical screw into the gearbox shaft and press the shaft with KM-564 into the gear block until it stops. Do not hammer the shaft to avoid damaging the splines
Lock the roller with a new retaining ring.
Screw the cover to the bearing shield, lubricate it with sealant or lay PVC tape, and tighten with a torque of 50 Nm. After tightening, the distance between the upper edge of the cover and the plane of the bearing shield should be a maximum of 4 mm, to achieve sufficient sealing.
Using a crowbar, loosen the clutch and remove 3 KM-450 clamps.
Screw the clutch cover to the clutch housing with a torque of 7 Nm.
Install the cable on the release lever and secure the safety clip to the screw thread of the cable.
Adjust the clutch pedal, see p. 9.4.
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