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Tips for CLUTCHES, Clutch Kit + Csc Clutch replacement steps and how it is implemented | Valeo Service

Fitting Instruction for CLUTCHES, Clutch Kit + Csc, 837352 - Valeo Service

Clutch replacement steps

<h3>1. Before disassembling the gearbox</h3>

It is necessary to have disassembled the subframe and the wishbones to allow a correct disassembly-reassembly operation of the gearbox.

&nbsp;

<h3>2. After disassembling the gearbox from the engine.</h3>

&nbsp;

1. Check the gearbox input shaft splines, checking that there is no damage or signs of excessive wear along the spline length.

&nbsp;

2. Lock the flywheel in rotation and remove the flywheel fixing bolts.

&nbsp;

3. Check the gearbox input shaft seal: verify that there is no oil coming from the gearbox. If there is a presence of oil, replace the gearbox input shaft seal..

Check engine crankshaft seal: Verify that there is no oil contaminating the flywheel. If there is a presence of oil, remove the flywheel and change the crankshaft seal.

&nbsp;

<h3>3. Prepare the CSC for assembly</h3>

&nbsp;

<ol>
	<li aria-level="1" style="list-style-type:decimal">Disassemble existing CSC from gearbox.</li>
	<li aria-level="1" style="list-style-type:decimal">On the replacement CSC, check for the presence of plastic plug (b) and clip (c)&nbsp; from figure 1.</li>
	<li aria-level="1" style="list-style-type:decimal">Assemble CSC on gearbox without removing the plug (b).</li>
	<li aria-level="1" style="list-style-type:decimal">Use the original CSC bolts, fasten the bolts applying a torque of 15 – 20 Nm.</li>
</ol>

<h3>4. Fasten the flywheel.</h3>

&nbsp;

Position carefully the new A-DMF Valeo on to the crankshaft center and tighten the bolts M10x1 mm with a progressive torque following a star sequence.&nbsp;

Avoid applying excessive torque. Tightening torque: 60 Nm + 50º

&nbsp;

<h3>5. Prepare the clutch for assembly.</h3>

&nbsp;

<ol>
	<li aria-level="1" style="list-style-type:decimal">Apply a small quantity of grease to the hub splines at approximately 5 mm from the hub extremity.</li>
</ol>

&nbsp;

<ol start="2">
	<li aria-level="1" style="list-style-type:decimal">Use a centering tool to position the driven plate onto the flywheel.</li>
</ol>

&nbsp;

<ol start="3">
	<li aria-level="1" style="list-style-type:decimal">Fasten the cover assy centering it with the pins and hand tightening 3 screws at 120º and checking that the driven plate remains stable and well centered with the centering tool.&nbsp;</li>
</ol>

 
Use screws supplied by Valeo&nbsp; M7x1 mm. Do not use any additional thread lock on the screws.

<h3>6. Fasten the clutch.</h3>

<ol>
	<li aria-level="1" style="list-style-type:decimal">Position the driven plate on to the flywheel using a centering tool (see photo).</li>
	<li aria-level="1" style="list-style-type:decimal">Fasten the cover assy centering it with the pins and hand tightening 3 screws at 120º and checking that the driven plate remains stable and well centered with the centering tool.&nbsp;</li>
	<li aria-level="1" style="list-style-type:decimal">Tighten smoothly each screw using a star-like sequence as per the tightening of the flywheel. The diaphragm fingers have to move as uniform as possible. Repeat the complete sequence approximately 3 times. It’s mandatory to use screws supplied by Valeo. Not following star like sequence can generate issues such as difficult gear shifting or slippage.</li>
	<li aria-level="1" style="list-style-type:decimal">Complete the fastening applying a torque of 20 Nm using a torque wrench and the previous star-like sequence.</li>
</ol>

&nbsp;

&nbsp;

<ol>
	<li aria-level="1" style="list-style-type:decimal">Check that the block pins are in place and that they are not damaged.</li>
</ol>

 
2.Position the gearbox coaxially with the engine crankshaft, supporting the gearbox weight with the appropriate tools such as the use of a hydraulic jack (see figure 2)

&nbsp;

<ol start="3">
	<li aria-level="1" style="list-style-type:decimal">Introduce the gearbox input shaft into the driven plate hub spline.</li>
</ol>

&nbsp;

<ol start="4">
	<li aria-level="1" style="list-style-type:decimal">Take care that the input shaft is introduced without shock. If necessary rotate the crankshaft to make the input shaft fitting easier.</li>
</ol>

Avoid that the weight of the gearbox be supported by the driven plate of the clutch during the assembly.

&nbsp;

<ol start="5">
	<li aria-level="1" style="list-style-type:decimal">Check that the gearbox is in full contact with the engine block and that the centering pins are well fitted and tighten the screws with the appropriate torque.</li>
</ol>

<h3>8. After the vehicle assembly.</h3>

<ul>
	<li>Verify that the clutch is working well.</li>
	<li>Disengage &amp; then re-engage the clutch and shift each gear ratio &amp; reverse.</li>
	<li>Ensure that there is no abnormal noise when engaging &amp; disengaging the clutch.</li>
	<li>Check that there’s no abnormal vibration or noise In neutral speed and up to speed 4000 rpm.</li>
	<li>Verify that there is no abnormal clutch sliding during driving conditions.</li>
</ul>