Note. These operations are performed without removing the engine and gearbox from the engine.
Jack up the vehicle and remove the clutch housing cover.
Unscrew the plug (see photo) rear cover of the gearbox.
Remove the circlip and remove the rear screw from the gearbox input shaft (see photo).
With a puller, remove the input shaft from the gearbox until it stops (see photo).
Disconnect the clutch cable from the clutch release lever by first removing the retaining clip.
Disengage the clutch and lock the clutch pedal in the depressed position.
Clamp the clutch cover with brackets KM 450 on vehicles with gearbox types «F10», «F13» or KM 526 on vehicles with gearbox types «F16», «F20».
Loosen the bolts securing the clutch cover to the flywheel and remove the clutch cover assembly with the driven disk, pulling them out through the opening. This releases the clutch disc.
Unscrew the bolt securing the clutch fork to the lever and remove the clutch release bearing.
Remove the lever from the clutch housing through the top, remove the clutch release fork.
Clutch installation is carried out in the reverse order of removal.
Install the lever, bearing and clutch release fork.
Apply a thin layer of grease to the splines of the clutch disc bushing.
Replace the clutch disc with the inscription «Getri-ebe seite» («Drive Side») to the clutch cover. Install the clutch cover assembly with the driven disk on the flywheel, aligning the mark on the flywheel with the recess on the clutch cover (see photo), and tighten the mounting bolts.
Slightly raise the driven disk and, moving the disk away, insert the input shaft of the gearbox into the splines of the driven disk bushing.
Note. If the clutch is installed on a removed engine, center the clutch disc relative to the flywheel with the KM 534 mandrel (see photo and drawing), simulating the splined end of the input shaft of the gearbox.
Tighten bolts securing clutch cover to flywheel.
Screw the rear bolt into the input shaft of the gearbox and, using the KM 449.2 tool, insert it until it stops.
Install a new retaining ring on the end of the input shaft of the gearbox.
Apply a special sealant to the thread of the plug or seal it with PVC film. To ensure tightness, screw the plug so that the distance between its end and the surface of the gearbox rear cover is no more than 4 mm.
Remove the three clamps.
Install the clutch housing cover.
Connect the clutch cable to the lever and secure it with the retaining clip.
Check and, if necessary, adjust the clutch pedal stroke as indicated below.
Lower the car.
Clutch pedal stroke adjustment
The clutch pedal has no free play, and its working stroke increases as the driven disk wears out.
The clutch pedal travel must only be adjusted if the clutch cable or clutch disc has been replaced. Measure with a ruler the distance between the center of the clutch pedal and the steering wheel with the clutch pedal released and depressed. Determine the difference between the results of the changes, which should be 138±7 mm. If necessary, remove the locking bracket of the clutch cable and, by rotating the tip of the cable that connects it to the clutch release fork lever, achieve the required size. After adjustment, fix the cable with a locking bracket.
Visitor comments