This is a routine activity in every workshop - but make sure you know every step. Be sure to read the tips below.
Here they are:
1. spoon/crowbar
2. torque wrench
3. socket wrench for dismantling the pressure cover
4. clutch disc centering pin
5. positioning pins
6. socket for turning the crankshaft
7. spring-loaded release tool for the thrust bearing retaining ring
8. open-end wrench for pilot bearing removal tool
9. pilot bearing removal tool
1. Pressure housing assembly
2. Clutch disc
3. Thrust bearing of the mechanical clutch actuation system
4. Assembly instructions
Before unscrewing the gearbox, it is necessary to disconnect the release bearing and release the clutch lever fork. First, use the crankshaft rotation socket (from the vehicle manufacturer) to rotate the flywheel. This will facilitate access to the ends of the bearing retaining ring in the clutch pressure housing. Insert the spring-loaded thrust bearing release tool through the service hole into the gearbox and engage it into the ends of the retaining ring. Use the bucket/crowbar as a lever, open the latch and remove the bearing and move the clutch lever with the fork towards the gearbox. Then check for any traces of grease around the flywheel. If not, carefully clean the flywheel surface. To do this, use solvent or brake cleaner and 150-grit sandpaper.
Using the appropriate bushing, start by installing a new pilot bearing. Reinstall the clutch disc centering pin to prevent it from falling. Before installation, make sure that the spline of the clutch disc fits the spline of the gearbox input shaft. Protect the clutch disc friction lining from contact with grease. It adversely affects the friction coefficient and may cause the clutch to slip. Reinstall the pressure housing positioning pins and secure the clutch pressure housing assembly. Lightly tighten the mounting screws with your fingers and then remove the positioning pins. Replace them with the original pressure housing mounting screws. In the next step, check the centering of the pressure housing relative to the flywheel and tighten the lower screws to determine its position.
Tighten the pressure housing mounting bolts, remembering that you will finally tighten them with a torque wrench. Never use an air wrench for this operation, as it may damage the thread. Torque values are listed in the manufacturer's instructions, as is the bolt tightening sequence. Then remove the four shipping latches of the pressure housing assembly and remove the centering pin.
Check the condition of the guide sleeve and gearbox input shaft. Before replacing the release bearing, it is necessary to dismantle the clutch lever fork. It is possible that they will need to be replaced, which depends on the mileage of the vehicle or their possible wear.
Now you can release the release bearing and remove it safely. Check the guide sleeve for grease and clean it. To do this, use solvent or brake cleaner and 150-grit sandpaper. Lubricate the fork shaft. Install a new thrust bearing and reattach the fork. Tighten their mounting to the appropriate torque using a torque wrench. Check that the fork moves on the shaft without excessive resistance or blocking. If the fork shaft or the fork itself shows wear, it is necessary to replace the entire fork.
Slide the transmission housing back onto the clutch pressure assembly and install the mounting bolts. Once the transmission is installed, insert the bucket/pry bar through the service hole (on some vehicles access to the bearing is through the slave cylinder) and press the new release bearing into the retaining ring latch. Press twice to make sure the ring is properly seated. Check that the snap ring ends are centered correctly. Then close the service port with a rubber, waterproof cap to protect the clutch housing from dirt and dust.
In a vehicle with an automated gearbox, it is necessary to perform appropriate adaptation using a dedicated diagnostic tool. It is advisable to conduct a test drive after each repair to verify the correct operation of the clutch actuation system and the clutch itself in various operating states.
Valeo supplies original equipment clutches for every second truck in Europe - both with manual and automated gearboxes. Detailed information about Valeo products is available in the catalog library.
