Clutch Disc: Service and Repair

Clutch Pressure and Driven Plate Replacement (LUJ, LUW with MF3, MZ0, or MZ4) (1.4L, 1.8L)

Special Tools

DT-6263 - Remover / Installer

For equivalent regional tools, refer to Special Tools (Tools and Equipment).

Removal Procedure

Note:
* To prevent damage to the spring tangs of pressure plate use DT-6263 - remover / installer to remove and install clutch pressure plate.
* Note the different lengths of the brackets for attaching DT-6263 - remover / installer to lower engine block.

1. Remove transmission. Refer to Transmission Replacement (Removal and Replacement).





Note: DT-6263 - remover / installer may only be attached to the engine block and not to the oil pan.

2. Attach DT-6263 - remover / installer (1) to engine block.

Note: Do not tighten the bolts yet.

3. Install 4 bolts (arrows) to engine block.




4. Attach a suitable clutch center guide (5) to DT-6263-30 - centering drift (4).
5. Fasten DT-6263 - remover / installer.

* Align DT-6263 - remover / installer to center.
* Insert DT-6263-30 - centering drift (2) in conjunction with clutch center guide through DT-6263 - remover / installer into clutch pressure plate and crankshaft center (arrow).
* Tighten knurled wheel (1).
* Tighten bolt (3).
* Tighten 4 bolts of DT-6263 - remover / installer to the engine block.




6. Preload clutch springs using DT-6263 - remover / installer.

* Move DT-6263 - remover / installer (1) that it rests against the spring tangs of clutch pressure plate.
* Turn DT-6263 - remover / installer clockwise to the stop.





Note: DISCARD the bolts.

7. Remove 6 clutch pressure plate bolts (1).




8. Release DT-6263 - remover / installer (1).

* Turn DT-6263 - remover / installer counterclockwise to the stop.
* Remove DT-6263-30 - centering drift (2) in conjunction with clutch center guide.




9. Remove clutch pressure plate (2) and driven plate (1).





Note: Clutch pressure plate and driven plates contaminated by foreign bodies (oil, cleaning agent etc.) have to be replaced. Check clutch driven plate for damage and friction rust in the hub profile and replace if necessary. Do not clean clutch pressure plate and driven plate with a high pressure cleaner or component washing machine.

10. Inspect clutch pressure plate and driven plate (1) and replace if necessary.

Inspect for:
* Excessive wear
* Burned friction surface
* Oil on friction surface
* Damaged spline hub
* Damaged springs

Note: The clutch driven plate has to be replaced if the lining projection is less than 0.5 mm (0.020 in) (arrows).

11. Inspect projection of lining at the clutch lining rivets.
12. Slide clutch driven plate onto the transmission input shaft and check for easy movement.

Installation Procedure

1. Clean 6 threads in flywheel for fastening clutch pressure plate.





Note: Lettering transmission side faces the transmission.

Center clutch driven plate using DT-6263-30 - centering drift (3) in conjunction with clutch center guide.

2. Install driven plate (1) and clutch pressure plate (2).




3. Preload clutch springs using DT-6263 - remover / installer.

* Move DT-6263 - remover / installer (1) that it rests against the spring tangs of clutch pressure plate.
* Turn DT-6263 - remover / installer clockwise to the stop.





Caution: Refer to Fastener Caution (Fastener Caution).

4. Install 6 NEW clutch pressure plate bolts (1) and tighten crosswise to 28 Nm (21 lb ft).




5. Remove DT-6263 - remover / installer (1) from engine block.

* Turn DT-6263 - remover / installer (3) counterclockwise to the stop.
* Remove DT-6263-30 - centering drift (2) in conjunction with clutch center guide (arrow).
* Remove 4 bolts of DT-6263 - remover / installer from engine block.

6. Install transmission. Refer to Transmission Replacement (Removal and Replacement).