Opel Frontera UE. Manual - part 1056

CLUTCH

7C–15

Clutch Assembly (6VD1, MUA)

Clutch Assembly (6VD1, MUA) and Associated Parts

201RS023

Legend

(1) Transmission Assembly
(2) Pressure Plate Assembly
(3) Driven Plate Assembly

(4) Release Bearing
(5) Shift Fork
(6) Fulcrum Bridge
(7) Flywheel Assembly and Crankshaft Bearing

Removal

1. Refer to “MANUAL TRANSMISSION” of Section 7B

for “REMOVAL AND INSTALLATION” procedure of
transmission assembly (1).

7C–16

CLUTCH

2. Use the pilot aligner J24547 to prevent the driven

plate assembly (3) from falling free.

201RS001

Legend

(2) Pressure Plate Assembly
(3) Driven Plate Assembly
(8) Pilot Aligner

3. Mark the flywheel, clutch cover and pressure plate lug

for alignment when installing.

4. Remove the release bearing (4) from the

transmission case.

201RS024

5. Remove the snap pin.  Remove the shift fork pin and

shift fork from the fulcrum bridge.

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6. Remove the fulcrum bridge bolts.  Remove the

fulcrum bridge (6) from the transmission case.

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CLUTCH

7C–17

D

Do not remove crankshaft bearing (7) except for
replacement.

D

Use the remover 5–8840–2000–0 and sliding
hammer 5–8840–0019–0 to remove the crankshaft
bearing.

015RW053

Inspection and Repair

Make necessary correction or parts replacement if wear,
damage, or any other abnormal condition are found
through inspection.

Pressure Plate Assembly

D

Visually check the pressure plate friction surface for
excessive wear and heat cracks.  If excessive wear or
deep heat cracks are present, the pressure plate
must be replaced.

201RS002

Pressure Plate Warpage

D

Use a straight edge and a feeler gauge to measure
the pressure plate friction surface flatness in four
directions.  If any of the measured values exceed the
specified limit, the pressure plate must be replaced.

Pressure Plate Warpage

Limit: 0.3 mm (0.012 in)

201RS003

Clutch Cover

D

Visually check the entire clutch cover for excessive
wear, cracking, and other damage.   The clutch cover
must be replaced if any of these conditions are
present.

201RS004

7C–18

CLUTCH

Clutch Set Force

1. Invert the pressure plate assembly.
2. Place a new driven plate over the pressure plate.  A

metal sheet with thickness of 8.0mm (0.315in) may
be used in place of the driven plate.

3. Compress the pressure plate assembly until the

distance becomes 12mm (0.472in).

4. Note the pressure gauge reading.  If the measured

value is less than the specified limit, the pressure
plate assembly must be replaced.

Clutch Set Force
Standard: 7208N (735 kg/1621lb)
Limit: 6669N (980 kg/1499lb)

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Diaphragm Spring Finger Height

1. Place a new driven plate or a 8.0mm (0.315in) spacer

beneath the pressure plate.

2. Fully compress the pressure plate and diaphragm

spring.
There are two ways to do this:

a. Use a bench press to press down on the assembly

from the top.

b. Tighten the fixing bolts.

NOTE: Preload on diaphragm spring finger must be
4998N (510 kg/1122lb) in direction of release, when
clutch cover assembly is bolted to the flywheel.

3. Measure the spring height from base to spring tip. If

the measured value exceeds the specified limit, the
pressure plate assembly must be replaced.

Spring Finger Height

Standard: 49.9 – 51.9 mm (1.965– 2.043 in)

201RW016

Driven Plate Assembly

D

Visually check the torsion spring for looseness,
breakage, and weakening. If any of these conditions
are discovered, the driven plate assembly must be
replaced.

D

Visually check the facing surfaces for cracking and
excessive scorching.  Visually inspect the facing
surfaces for the presence of oil or grease.  If any of
these conditions are discovered, the facing must be
cleaned or replaced.

D

Check that the driven plate moves smoothly on the
transmission top gear shaft spline.  Minor ridges on
the top gear shaft spline may be removed with an oil
stone.

201RS007