Skip to main content

Introduction

Clutch change with engine extraction.

Differences may appear in the photos, my vehicle is no longer completely original, but the steps are identical

  1. Remove the 2 battery terminals Remove the 2 battery terminals
    • Remove the 2 battery terminals

  2. Start by disconnecting the lights (3 terminals + 1 pin) on both sides The pin is located on the back of the bulb (green circle) on an original bulb Unscrew the 2 nuts securing the hood hinges
    • Start by disconnecting the lights (3 terminals + 1 pin) on both sides

    • The pin is located on the back of the bulb (green circle) on an original bulb

    • Unscrew the 2 nuts securing the hood hinges

  3. Place a recovery basin under the lower radiator hose then disconnect this hose See step 1 Also disconnect the upper hose
    • Place a recovery basin under the lower radiator hose then disconnect this hose

    • See step 1

    • Also disconnect the upper hose

    • As well as the hose coming from the expansion tank

  4. Unplug the fan I have 2, ignore the second one
    • Unplug the fan

    • I have 2, ignore the second one

  5. Unscrew the 2 upper fixing screws Unscrew the 2 lower fixing nuts Remove the radiator by gently pulling it upwards
    • Unscrew the 2 upper fixing screws

    • Unscrew the 2 lower fixing nuts

    • Remove the radiator by gently pulling it upwards

  6. Disconnect the return spring Disconnect the return spring
    • Disconnect the return spring

  7. Disconnect the guide spring Disconnect the guide spring
    • Disconnect the guide spring

  8. Unscrew the 2 lever retaining screws Completely extract the lever by pulling it into the passenger compartment (as if to shift into 4th gear) Completely extract the lever by pulling it into the passenger compartment (as if to shift into 4th gear)
    • Unscrew the 2 lever retaining screws

    • Completely extract the lever by pulling it into the passenger compartment (as if to shift into 4th gear)

  9. Unscrew the remaining fixing nuts Unscrew the remaining fixing nuts Unscrew the remaining fixing nuts
    • Unscrew the remaining fixing nuts

  10. Unscrew the remaining fixing nuts Extract the crosspiece
    • Unscrew the remaining fixing nuts

    • Extract the crosspiece

  11. Completely unscrew the speedometer cable retaining screw
    • Completely unscrew the speedometer cable retaining screw

    • Extract the cable by pulling it upwards

  12. Unscrew the swan neck retaining screws Extract the swan neck
    • Unscrew the swan neck retaining screws

    • Extract the swan neck

  13. With the vehicle on the ground, completely unscrew the universal joint nut If your rims are solid, remove the wheel, raise the vehicle and ask someone to brake. Raise the vehicle and remove the wheel
    • With the vehicle on the ground, completely unscrew the universal joint nut

    • If your rims are solid, remove the wheel, raise the vehicle and ask someone to brake.

    • Raise the vehicle and remove the wheel

    • Place a basin under the gearbox drain plug, then drain the gearbox.

  14. Remove the 2 upper ball joints (Steering and suspension) Remove the 2 upper ball joints (Steering and suspension)
    • Remove the 2 upper ball joints (Steering and suspension)

  15. Extract the universal joint on the wheel side by pushing it towards the box This is perfect, you have to play with the angle of the cardan Then pull the gimbal towards you to remove it
    • Extract the universal joint on the wheel side by pushing it towards the box

    • This is perfect, you have to play with the angle of the cardan

    • Then pull the gimbal towards you to remove it

  16. Hold the spindle to avoid straining the brake hose
    • Hold the spindle to avoid straining the brake hose

  17. Unscrew the 2 steering column retaining screws Unscrew the 2 rack fixing screws (left and right) Do not lose or mix up the rack fixing shims!
    • Unscrew the 2 steering column retaining screws

    • Unscrew the 2 rack fixing screws (left and right)

    • Do not lose or mix up the rack fixing shims!

    • Extract the rack

  18. Unscrew the throttle cable retaining nut and disconnect the return spring. Disconnect the choke cable
    • Unscrew the throttle cable retaining nut and disconnect the return spring.

    • Disconnect the choke cable

  19. Disconnect the fuel supply hose and seal it Disconnect the fuel supply hose and seal it
    • Disconnect the fuel supply hose and seal it

  20. Disconnect the alternator wiring harness
    • Disconnect the alternator wiring harness

    • Disconnect the wire connecting the coil to the distributor

  21. Place the giraffe and hook the motor, put the chain under slight tension Unscrew and remove the 2 upper gearbox mounting screws Loosen the lower screws slightly
    • Place the giraffe and hook the motor, put the chain under slight tension

    • Unscrew and remove the 2 upper gearbox mounting screws

    • Loosen the lower screws slightly

    • Unscrew the 2 engine mounting nuts (left and right)

    • Personally, I hold on to the alternator mounting bracket, with caution.

  22. Extract the engine, gently checking that nothing has been forgotten
    • Extract the engine, gently checking that nothing has been forgotten

  23. Unscrew the 5 screws securing the bottom plate (2 on each side + 1 in the middle) Unscrew the 3 starter fixing screws and remove it
    • Unscrew the 5 screws securing the bottom plate (2 on each side + 1 in the middle)

    • Unscrew the 3 starter fixing screws and remove it

  24. Loosen the water pump belt by unscrewing the tensioner Remove the camshaft pulley Remove the camshaft pulley
    • Loosen the water pump belt by unscrewing the tensioner

    • Remove the camshaft pulley

  25. Unscrew the 4 fixing screws of the box then extract the box by pulling it in the axis of the engine Unscrew the 4 fixing screws of the box then extract the box by pulling it in the axis of the engine Unscrew the 4 fixing screws of the box then extract the box by pulling it in the axis of the engine
    • Unscrew the 4 fixing screws of the box then extract the box by pulling it in the axis of the engine

  26. Gradually unscrew the 6 clutch mechanism retaining screws Gradually unscrew the 6 clutch mechanism retaining screws
    • Gradually unscrew the 6 clutch mechanism retaining screws

  27. Place the new clutch disc and mechanism on the flywheel, in the same direction as when removing the previous one, taking care to center the assembly correctly. Gradually tighten the mechanism fixing screws in quarter turns, alternating in the order indicated, up to 15Nm.
    • Place the new clutch disc and mechanism on the flywheel, in the same direction as when removing the previous one, taking care to center the assembly correctly.

    • Gradually tighten the mechanism fixing screws in quarter turns, alternating in the order indicated, up to 15Nm.

    • Tightening order: Red => Yellow => Blue => Orange => Green => Purple; Red => yellow etc ...

  28. Unclip the "springs" securing the stop using a screwdriver Remove the stop and clean the axle Remove the stop and clean the axle
    • Unclip the "springs" securing the stop using a screwdriver

    • Remove the stop and clean the axle

  29. Regrease the axle and put the new stop in place, reclip the "springs" using a screwdriver as well.
    • Regrease the axle and put the new stop in place, reclip the "springs" using a screwdriver as well.

  30. Reconnect the engine-gearbox assembly, if the clutch is well centered this should not cause any problems.
    • Reconnect the engine-gearbox assembly, if the clutch is well centered this should not cause any problems.

    • Proceed to reassemble the various elements in the reverse order of disassembly.

    • Don't forget to put oil back in the box

    • Bleed the cooling circuit

Finish Line

6 other people completed this guide.

hrmuller t

Member since: 09/04/2017

3,352 Reputation

67 Guides authored

0 Comments

Add Comment

View Statistics:

Past 24 Hours: 1

Past 7 Days: 11

Past 30 Days: 73

All Time: 8,107