Clutch assembly/driven disc and release bearing (throw-out bearing) — K1.8 (Freelander 1)

Dismantling

1. Disconnect the negative battery terminal.

2. Remove the gearbox.

MECHANICAL TRANSMISSION - PG1, Gearbox, Gearbox.

3. Remove the release bearing from the guide sleeve and from the clutch release fork.

4. Check the release bearing for wear or damage and replace if necessary.



5. Place a flat disc on the diaphragm spring petals. Using a feeler gauge, measure the gap between the disc and the petals. The maximum permissible gap is 1.0 mm. A deviation of one petal by an amount exceeding the permissible value can be ignored.



6. Install the LRT-12-190 flywheel stopper onto the engine and secure it with the bolt.



7. Gradually loosen and remove the 6 bolts securing the clutch housing to the flywheel.



8. Remove the clutch cover and driven disc.

9. Check the pressure plate for wear or oil contamination. Replace the pressure plate if necessary.

10. Measure the thickness of the driven disk, replace the driven disk if its thickness is less than the permissible value of 5.6 mm.

11. Measure the rivet recess, replace the driven disc if the rivet recess is less than 0.2 mm.



12. Using a straightedge and feeler gauge, check the disc surface geometry at four different points. Replace the disc if the warpage exceeds the permissible value of 0.18 mm.

Installation

1. Clean the pressure plate, flywheel, dowel pins and their holes.

2. Check the flywheel running surface for scoring or other damage. Replace the flywheel if the running surface is damaged or worn.

3. Lubricate the splines of the driven disk with molybdenum disulfide grease.

4. Place the driven disc on the pressure plate with the 'FLYWHEEL SIDE' marking facing the flywheel.



5. Place the driven disk on the pressure plate and insert the centering mandrel, LRT-12-151.



6. Install 6 bolts securing the clutch housing to the flywheel, tighten the bolts just enough to hold the driven disk in the center position. Remove the LRT-12-151 centering mandrel from the clutch housing.

7. Gradually tighten the bolts in a criss-cross pattern to a torque of 25 Nm.

8. Remove the LRT-12-190 centering sleeve.

9. Clean the clutch release fork and release bearing bushing.

10. Apply molybdenum disulfide grease to the release bearing bushing.

11. Insert the release bearing into the clutch release fork and place it onto the release bearing sleeve.

12. Press the clutch release fork several times to ensure that the bearing is seated correctly and moves normally along the sleeve.

13. Install the gearbox.

MECHANICAL TRANSMISSION - PG1, Gearbox, Gearbox.

14. Connect the negative battery terminal.