Removal and installation of clutch Opel Astra H

The main malfunctions in the Opel Astra, the elimination of which requires the removal and disassembly of the clutch:

Useful advice

If the clutch fails, we recommend replacing all its elements at the same time (driven and pressure plates, clutch release bearing): the work of replacing the clutch is laborious, and the life of undamaged clutch elements has already been reduced, and if they are installed again, it may be necessary to replace the clutch again after relatively low mileage.

You will need: a “11” wrench (a socket head is more convenient), a mounting blade, a mandrel for centering the driven disk.

1. Remove a transmission (Removal and installation of a transmission see).

2. If you install the old pressure plate, mark in any way (for example, with paint) the relative position of the disc casing and the flywheel in order to set the pressure plate in its original position (to maintain balance).

3. Holding the flywheel with a mounting spatula (or a large screwdriver) from turning, unscrew the six bolts securing the clutch pressure plate casing to the flywheel (for clarity, the photo was taken on the removed engine). Loosen the bolts evenly: each bolt has two turns of the wrench, moving from bolt to bolt in diameter.

Note

This is how the clutch cover bolts to the engine flywheel are located.

4. Remove the clutch pressure and driven discs from the flywheel while holding the driven disc.

5. Examine a conducted disk of coupling. Cracks on the details of the driven disk are not allowed.

6. Check the degree of wear of the friction linings. If the rivet heads are sunk by less than 0.3 mm, the surface of the friction linings is oily, or the rivet connections are loose, then the driven disk must be replaced.

Note

If overlays of a conducted disk are greased, check up a condition of an epiploon of a primary shaft of a transmission. It may need to be replaced.

7. Check up reliability of fixing of damper springs in sockets of a nave of a conducted disk, trying to move them in sockets of a nave by a hand. If the springs move easily in their seats or are broken, replace the disc.

8. Check up beating of a conducted disk if its warping is found out at visual survey. If the runout is greater than 0.5 mm, replace the disc.

9. Inspect the working friction surfaces of the flywheel ...

10. ... and the pressure plate, paying attention to the absence of deep scratches, scuffs, nicks, obvious signs of wear and overheating. Replace defective units.

11. If the rivet connections of the casing and pressure plate parts are loose, replace the pressure plate assembly.

12. Visually assess the condition of the pressure plate diaphragm spring. The presence of cracks on the diaphragm spring is not allowed. Places A of contact between the petals of the spring and the clutch release bearing must be in the same plane and not have obvious signs of wear (wear should not exceed 0.8 mm). Otherwise, replace the pressure plate assembly.

13. Inspect the connecting links of the casing and disc. If the links are deformed or broken, replace the pressure plate assembly.

14. Visually evaluate the condition of the pressure spring support rings on the outer and inner sides of the spring. Rings must be free of cracks and signs of wear. Otherwise, replace the pressure plate assembly.

15. Before installing the clutch, check the ease of movement of the driven disk along the splines of the input shaft of the gearbox. If necessary, remove the causes of seizing or replace defective parts.

16. Apply high-melting grease to the driven disc hub splines.

17. When mounting the clutch, first install the driven disk using a mandrel ...

Note

Install the driven disc on your Opel Astra so that the inscription "FLYWHEEL SIDE" is directed towards the flywheel (the protruding part of the disc hub must be directed towards the diaphragm spring of the clutch housing).

18. ... and then the casing of the pressure plate, aligning the marks applied before removing it, and screw in the bolts securing its casing to the flywheel.

19. Screw the bolts with a torque of 15 Nm evenly, one turn of the wrench each, alternately moving from bolt to bolt along the diameter.

20. Remove the mandrel and install the gearbox.

21. Check up operation of coupling (Check and adjustment of a course of a pedal of a drive of deenergizing of coupling see).

• Source http://www.automnl.com/model/opel_astra_h2/316/