Attention! Dust, as a product of friction lining wear, may contain asbestos, which is hazardous to health. DO NOT blow it off with compressed air or inhale it. DO NOT use gasoline or gasoline-based solvents to remove dust. Use a special clutch cleaner or methanol to wash the dust into a container. After wiping the clutch with a rag, put it together with the wear products washed off with a special liquid in a container, marking it.
Withdrawal
1. Remove the gearbox as described in chapter 7A.
2. Before removing the discs, mark the position of the clutch basket relative to the flywheel with a marker or chalk.
3 Working in diagonal sequence, gradually loosen the basket-to-flywheel bolts with a hex key, loosening them half a turn at a time, until the spring is released and the bolts can be removed by hand. Having unscrewed the bolts two or three turns, check if the basket is stuck on the guide pins; pry it off the flywheel with a screwdriver if necessary. After this, unscrew the bolts and remove the basket.
4. After removing the basket, remove the friction disc, remembering which side to install it back.
Examination
5. Before cleaning the clutch, read the warning at the beginning this chapter. Remove dust using a clean cloth in a well ventilated area.
6. Check the wear of the diaphragm spring petals (pic. 6.6). If they are half worn, the basket must be replaced.
7. Check the contact surfaces of the clutch friction disc for signs of wear, damage or contamination. If the friction material has cracks, burn marks, gouges, dirt, oil (shiny black spots), worn, replace the friction disc.
8. If the friction linings are intact, check the disk hub (pic. 6.8). Rivets must not be damaged, vibration damper torsion springs must not be broken or loose in their sockets, splines must not be worn or damaged. If defects are found, replace the disc.
9. Check the contact surfaces of the flywheel and pressure plate. They must be absolutely even and smooth. no scratches or cracks, no signs of overheating. If defects are found that cannot be removed with sandpaper, it may make sense to grind the flywheel, otherwise replace the part.
10. Before assembly, clean all parts from dirt and dust. Apply a thin coat of high temperature grease to the friction disc hub splines. If a new clutch pressure plate is installed, it may be coated with preservative grease. Grease can only be removed from the contact surface of the disc, removing it from other parts reduces the service life "baskets".
Installation
11. Install the friction disc so that the protruding part of its hub looks outward from the flywheel. The disc must also be marked by the manufacturer on which side to install it. If necessary, use the mandrel (pic. 6.11).
12. Install the clutch basket on the flywheel, using the guide pins, aligning the marks made during removal (if the old basket is installed).
13. Screw in the basket mounting bolts, tightening them only by hand so far, so that the friction disc can be displaced.
14. Now you need to center the friction disc so that when installing the gearbox, its input shaft passes through the splines in the disc and hits the center of the crankshaft. It is possible to center the friction disc with a screwdriver by inserting it into the central hole of the disc and crankshaft and moving the disc until the centers of the holes are aligned. This task can be facilitated by a mandrel in the form of a gearbox input shaft, which can be purchased from a dealer, or ordered to be made in a lathe workshop. Good results can be obtained by winding the appropriate amount of electrical tape on a suitable piece of a round stick or a long bolt that fits snugly into the crankshaft hole.
15. Having centered the friction plate, gradually tighten the pressure plate fastening bolts in a diagonal sequence to the prescribed torque. After tightening the bolts, remove the centering mandrel (pic. 6.15).
16. Check the softness of the release bearing and, if necessary, replace it as described in paragraph 7.
17. Install the gearbox as described in chapter 7A.
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