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NOVEMBER 2021 AFTERMARKET 49 www.aftermarketonline.net remove both front wheels, inner wheel arch liners and then raise lift and remove alloy under guard framework (Fig.4). Remove front driveshafts by unscrewing hub nuts and spline bolts retaining inner CV joints, then release both bottom ball joints. Take away transfer box from gearbox, mark position of propshaft onto transfer box, unclip oil level sensor wiring loom from retaining clip, disconnect exhaust front pipe sleeves and remove rubber mounting assembly. Next, undo three 12-point bolts from transfer box to cushion drive assembly (Fig.5), remove lower gearbox pendulum mounting (Fig.6), ease engine and gearbox forward and disconnect propshaft from transfer box and support, as required. Drain gearbox oil and then undo O/S/F driveshaft flange using a long 6mm Allen key, disconnect transfer box retaining bracket bolts and then four main body securing bolts. At this point, transfer box can be removed and secured. Undo lower bell housing bolts, leaving two easily- accessible bolts in position to retain gearbox, then remove starter motor. Support engine using either a brace bar, sub- frame support or second transmission jack, then remove gearbox mounting, lower engine/transmission assembly to aid gearbox removal, support gearbox using a transmission jack, undo final bell housing bolts and ease gearbox away from engine. Once clear, lower transmission jack and place gearbox in a safe area. Clutch replacement Undo six clutch retaining bolts (Fig.7) and remove clutch cover and plate assembly. Alistair continued: “Upon inspecting the clutch plate. it was confirmed that the clutch had reached end of its service life, as the friction material had worn close to the rivets. The DMF was replaced on customer’s request.” With DMF removed, inspect back of engine for any oil leaks and rectify as required, clean back of engine with clutch and brake dust cleaner and mount new DMF. Insert new bolts and tighten to manufacturer’s torque, and de-grease clutch surface on the flywheel. Focusing on gearbox (Fig. 8), remove CSC, inspect bell housing area for oil leaks and rectify as required, clean bell housing area, confirm CSC mounting surface is clean, FIG.1 mount it and ensure retaining bolts have tightened correctly. Do not operate or squeeze CSC as this could damage new CSC. Apply light smear of high-melting point grease to gearbox input shaft splines, mount new clutch plate onto them, which will confirm clutch plate is correct, and evenly distribute grease. Remove clutch plate and wipe off excess grease. De-grease clutch pressure plate surface, then, using clutch alignment tool, mount new clutch onto DMF. Next, fit clutch bolts and torque to manufacturer’s specification. Before re-fitting gearbox, flush out old clutch fluid and replace it with new. Also, ensure gearbox alignment dowels are located correctly. Mount gearbox onto transmission jack, ease into position and align gearbox to engine. Once in position and located on dowels, secure with two bell housing bolts. Alistair added: “Refit in reverse order of removal. When the battery has been reconnected, reset all affected electrical consumers, replenish the gearbox oil with the correct quantity and grade of oil. Schaeffler’s advice when bleeding this clutch is to pressure bleed at 2.0 bar. Always carry out a full road test to ensure a quality repair.” www.repxpert.co.uk FIG.2 FIG.3 FIG.4 FIG.5 FIG.6 FIG.7 FIG.8