...mandrel for centering the driven disk (can be made from the primary shaft of the gearbox by removing the gears).
1. Remove the gearbox (see "Removal and installation of the gearbox").
2. If you are going to install the old pressure plate, mark the relative positions of the pressure plate housing and the flywheel in any way so that you can install the pressure plate in the same position as before removal (to maintain balance).
3. Install the mandrel into the pressure plate hole.
Note: You can remove the clutch without a mandrel, but hold the driven disk: it may fall out of the clutch housing.
4. While holding the flywheel with a screwdriver to prevent it from turning, remove the six bolts securing the clutch pressure plate housing to the flywheel. Loosen the bolts evenly: one turn of the wrench each time, moving from bolt to bolt according to diameter.
5. Remove the clutch housing assembly with the pressure plate.
6. Remove the driven disk together with the mandrel.
7. Cracks on the driven disk parts are not allowed. Check the wear of the friction linings 1. If the heads of the rivets 2 are recessed by less than 0.2 mm, the surface of the friction linings is oily or the riveted joints are loose, the driven disk must be replaced. Check the reliability of the fixation of the damper springs 3 in the sockets of the driven disk hub; if the springs are broken, the disk must be replaced.
8. Check the runout of the driven disk if warping is detected during visual inspection. If the runout exceeds 0.5 mm, replace the disc.
9. Inspect the working friction surfaces of the flywheel and pressure plate, paying attention to the absence of deep scratches, nicks, burrs, obvious signs of wear and overheating. Replace defective components.
10. Assess the condition of the disc spring 1 of the pressure plate by visual inspection. The presence of cracks on the spring is not allowed. The contact points of the spring petals with the clutch release bearing must be in the same plane and have no obvious signs of wear (wear should not exceed 0.8 mm). Otherwise, replace the pressure plate assembly. If the riveted connections of the 2 parts of the casing and the pressure plate are loose, replace the pressure plate assembly.
11. Assess the condition of the pressure spring support rings by visual inspection. The rings must not have cracks or signs of wear. Otherwise, replace the pressure plate assembly.
12. Before installing the clutch, check the ease of movement of the driven disk along the splines of the input shaft of the gearbox. If necessary, eliminate the causes of jamming or replace defective parts.
13. Please note that when installing the driven disc into the pressure plate housing, the more protruding part of the hub should be directed towards the pressure spring.
14. When installing the clutch, first install the driven disk using a drift...
15. ...then place the pressure plate casing on the three centering pins and screw in the casing mounting bolts to the flywheel.
16. While holding the flywheel with a screwdriver from turning, evenly tighten the bolts securing the clutch to the flywheel: one turn of the wrench each, moving from bolt to bolt according to diameter. The tightening torque of the bolts is specified in Appendix 1.
17. Remove the mandrel and install the gearbox.
18. Install the lower end of the clutch release cable to the gearbox and restore the original adjustment of the clutch release cable (see "Replacing the clutch release cable").
Note: Before restoring the original cable adjustment, it is necessary to return the clutch slave disk lining wear compensation mechanism to its original state, since when the clutch disk is completely worn out, the wear compensator slider will remain in the extreme lower position. After installing a new, unworn driven disc, the length of the threaded portion of the lower end of the cable may not be sufficient to restore the initial position of the cable.
Note: To return the wear compensation mechanism to its original position, set the dimension L (see "Replacing the clutch release cable") between the leash and the clutch release fork lever, move the clutch pedal up to the stop - the mechanism spring will automatically return the slider to its original position. Then check the L size again and adjust if necessary.