Dual Dry Clutch - FITTING INSTRUCTIONS

DDC INSTALLER TOOL

This is mandatory to install the new DDC - PN: DDCT-01

DDC REMOVER TOOL

This tool is mandatory to remove the old DDC - PN: DDCT-02

ACTUATOR ADJUSTER JIG

This tool is mandatory to reset the DDC actuator without a diagnostic tool - PN: DDCT-04

STEP 1 - Remove the gearbox using a hydraulic lift table.

STEP 2 - Place gearbox on a workbench in a stable horizontal position.

STEP 3 - Remove the snap ring from the upper hub of DDC package with the snap ring pliers

STEP 4 - Remove manually the top hub of DDC package

STEP 5 - Remove the 2nd snap ring from the shaft with a screwdriver

STEP 6 - Mount DDC Remover (DDCT-02) on the DDC, the axe must be in contact with primary shaft and each leg must be placed below the cover plate

STEP 7 - Screw it using a wrench (19) until DDC bearing is completely removed from the primary shaft.

STEP 1 - Remove the plastic fork cover fixed by two screws. Use flat wrench 12

STEP 2 - Remove the 5 screws that fix the actuator to the gearbox. Use flat wrench 12

STEP 3 - Remove manually the two forks fixed on the actuator

STEP 4 - Remove manually the two forks fixed on the actuator

STEP 1 - Remove the 3 screws that fix the forks to the gearbox. Use Allen wrench 5

STEP 2 - Remove both release bearings and 3 screws that fix the guide tube to the gearbox. Use Allen wrench 5

STEP 3 - Remove guide tube and clean gearbox housing

STEP 4 – Prepare to add the quantity of grease provided by Valeo in box

STEP 5 – Add the quantity of grease necessary in forks, bearings and spline shaft

STEP 6 - Tighten 3 screws (M6) to fix new guide tube to gearbox housing. Use Allen wrench 5 - Tightening torque 15Nm

STEP 7 - Tighten 3 screws (M6) to fix new forks to gearbox housing. Mount release bearing. Use Allen wrench 5- Tightening torque 15Nm: only fits in one position

STEP 8 - Check if the release bearings can slide correctly by acting manually on the dual fork

STEP 1 - Fix the actuator on the actuator adjuster tooling (DDCT-03) and tighten 3 screws to fix it correctly

STEP 2 - Hook the lever with the first cylinder and pull CAREFULLY it until feel the stop, push the ruler to the end and measure the distance : 59 mm

STEP 3 – Hook the tooling with the second cylinder and pull CAREFULLY it until feel the stop end and measure the distance on the ruler: 32 mm

STEP 4 - Push completely until stop end the cylinder and insert the actuator adjuster (DDCT-04) on the hole. The final length of both cylinders must be 72mm.

STEP 5 - Rotate the adjuster to get the correct length.

4 revolution will be 1mm of cylinder displacement. Rotations: Lever 1 : 72 mm – 59mm = 13mm * 4 = 52 tool turns Lever 2 : 72 mm – 32mm = 40mm * 4 = 160 tool turns

STEP 6 - Check that the final length is correct (72 mm).

Hook the lever with the first cylinder and pull CAREFULLY it until feel the stop, push the ruler to the end and measure the distance : 72 mm Repeat the operation for the 2nd cylinder

STEP 7 - Mount the actuator on the gearbox and insert the cylinder on the forks manually

STEP 8 - Tighten all the screws of the actuator on the gearbox . Use flat wrench 12 .Tightening torque 25Nm

STEP 9 - Reinstall the plastic top with 2 screws. Use flat wrench 12. Tightening torque 25 Nm

STEP 1 - Fit the DDC tool (DDCT-02) on the new DDC package. Each leg must be placed and ensure below the cover plate

STEP 2 - Fit the DDC on the gearbox main shaft. Be very careful with the weight

STEP 3 - Remove the DDC tool DDCT-02 and put the cylinder of the DDC installer tool (DDCT-01) on the main shaft (to push the central bearing)

STEP 4 - Place the complete DDC installer (DDCT-01) on the gearbox

STEP 5 - Fix the DDC installer tool (DDCT-01) on the gearbox on 3 holes with original gearbox screws

STEP 6 - Screw it using a wrench 19” until DDC is completely assembled . When the bearing reach its position, the DDC package will have free play .

STEP 7 - Mount the inner snap ring a pliers

STEP 8 - Insert manually the hub on the DDC package

STEP 9 – Insert the outer snap ring with a pliers

STEP 1 - Remove the 8 M10 bolts to extract the flywheel. Remember block the flywheel with a specific tool

STEP 2 - Inspect the crankshaft seal, if any presence of leak or damage . Repair it if needed before fit the new flywheel

STEP 3 - Position the new flywheel tightening manually the bolts M10x1

STEP 4 - Apply progressive torque following a star sequence. Tightening torque 110Nm

STEP 4 - Reassembly gearbox using the hydraulic lift table smoothly until DDC and flywheel are completely fitted