Clutch replacement

Open the engine hood

Raise the vehicle using a jack and wedge it with 2 axle stands so that the vehicle is no longer resting on its front wheels.

Remove the 2 front wheels

Operations to be carried out on both sides:

Wedge a large flathead screwdriver into one of the disc vents and against the caliper.

Unscrew and remove the universal joint nut using a 30mm 12-point socket.

Operations to be carried out on both sides:

Unscrew the steering ball joint fixing nut with a 16 wrench until it is flush with the ball joint screw. Then tap it with a mallet to remove the ball joint and then finish removing the nut.

Under the vehicle:

Unscrew and remove the 2 screws securing the anti-roll bar. Then remove the anti-roll bar.

Unscrew and remove the 2 lower engine mount fixing screws. Then remove the engine mount.

Place a drain pan under the gearbox drain screw and unscrew the drain screw using a drain wrench to drain the gearbox.

Wait until all the oil has drained, then replace the drain screw and tighten securely.

Remove the drain pan from under the vehicle.

Operations to be carried out on both sides:

To separate the suspension from the suspension arm, unscrew and remove the 3 suspension ball joint fixing screws using a 16mm wrench and an Allen key.

Pull the suspension towards you so as to release the universal joint.

Pull the gimbal towards you to remove it.

At the engine compartment level:

Remove the air intake pipes.

Remove the battery cover.

Remove the computer cover.

Pull the calculator upwards to remove it from its housing and position it in front of the battery.

Disconnect the battery terminals starting with the negative terminal.

Unscrew the battery fixing screw using a 10 wrench, and remove the battery from its housing.

Unscrew the two battery tray mounting screws and remove the battery tray.

When removing the tray, be sure to unclip all the cable ties attached around the tray.

Unscrew and remove the battery tray support fixing screw using a 10 wrench and remove the support.

When supporting, be sure to unclip all the cable ties attached to the support.

Disconnect the reverse sensor from the gearbox.

Disconnect the negative cable and connect it to the gearbox using a 13mm wrench.

Remove the 2 gearshift cables from the gearbox by levering under the Silentbloc with a 13 flat spanner.

Remove the cable support fixing screw using a 13 mm wrench.

Under the vehicle, unscrew the second screw of the cable support using a 13 wrench and release the cable support.

In the engine compartment, unscrew the two clutch receiver mounting screws using a 13mm wrench. And remove the receiver from the gearbox.

Do not disconnect the clutch receiver, just remove it from the gearbox and place it nearby.

Remove the 2 nuts securing the cable support fixed to the gearbox using a 13 wrench.

Pull the cable holder and place it a little higher to remove it from the fixing rods

Remove the upper starter mounting screw using a bit or an H6 Allen key.

Under the vehicle: Unscrew and remove the two starter mounting screws using a bit or an H6 Allen key. (The one that is easily accessible but not visible is located above.)

Pull the starter to the side to remove it from its housing; there is no need to disconnect it.

Under the vehicle, using a jack and a wooden block, support yourself under the oil pan.

At the engine compartment level, unscrew and remove the 2 screws from the engine support on the gearbox using a 16 wrench.

Unscrew and remove the 4 screws from the engine support on the body using a 16 wrench.

Remove the engine mount.

Unscrew and remove the 3 screws securing the support to the gearbox using the 13 mm wrench.

Remove the support.

The gearbox removal operation now begins

Unscrew and remove the gearbox fixing screw at the front of the engine compartment using a 13 wrench.

Unscrew and remove the gearbox mounting nut at the front of the engine compartment using a 16 mm wrench.

Unscrew and remove the gearbox fixing screw at the engine compartment using a 16 wrench.

Unscrew and remove the gearbox fixing nut at the engine compartment using a 16 wrench. It is located near the starter screw previously removed.

Under the vehicle:

Unscrew and remove the gearbox fixing screw located below the starter using a 13 wrench.

Unscrew the 2 box fixing screws located near the exhaust pipe using a 13 wrench.

Do not unscrew these last two screws completely; they must not come into contact with the exhaust pipe to avoid damaging it.

To remove the gearbox, you need 2 people. -One supporting the gearbox and pulling it out. -The other finishes unscrewing the 2 screws mentioned above.

Place the gearbox on the ground and remove it from under the vehicle.

We now visualize the clutch mechanism fixed on the flywheel.

Unscrew and remove the 6 clutch mechanism fixing screws using a bit or an Allen key. Remove the clutch mechanism and its disc.

Prepare the new clutch mechanism: Place the clutch disc under the mechanism and center it using the clutch centering tool.

Make sure the clutch disc is fitted in the correct direction. The side marked GearBox side must be located on the box side

Place the new clutch disc on the flywheel using the 6 clutch mechanism fixing screws using a bit or an Allen key. Tighten to a torque of 20N.m

Remove the clutch disc centering tool.

Gearbox side:

Check that the clutch fork is not loose at its attachment point, otherwise replace it.

Remove the clutch fork by pulling it towards you.

Unscrew and remove the 3 fixing screws of the guide sleeve using a 8 wrench. Remove the guide sleeve by pulling towards you. Replace the guide sleeve. Refit the 3 fixing screws and tighten to a torque of 10N.m

Grease the clutch fork bearings

Insert the new clutch release bearing into its housing on the fork.

Make sure that the clutch release bearing lugs are properly seated in the fork.

Place the clutch fork with the stop back on the gearbox and press it firmly to lock it onto its support.

Replace the transmission oil seals on both sides of the gearbox. Extract the old seals with a screwdriver then insert the new ones with a plastic mallet.

Proceed to refit the gearbox and various components in the reverse order of removal from step 14 to step 8 inclusive.

After step 8, carry out step 5 (Replacing the universal joints and fixing the suspension arms).

Proceed to fill the gearbox, to do this remove the air vent plug and insert a funnel. Fill with 2 liters of 75w80 oil. Then replace the cap.

Repeat steps 7 to 1 to complete the reassembly.