A single-disc clutch is installed in Opel Kadett cars, dry with central disc spring This type of clutch has an almost constant engagement force throughout its service life and is prone to skidding, when the linings are near their wear limit. Clutches on gasoline and diesel engines differ in size.
Replacing the clutch disc
The described activities can be performed without removing the drive unit from the car.
■ Raise the car or drive into the canal.
■ Remove the screw plug from the rear cover
■ Remove the retaining ring from the visible main shaft journal and unscrew the cap screw.
■ Pull out the main shaft of the gearbox as far as it will go.. The puller is screwed into the hole after the removed cylinder head bolt
■ Remove the bolts securing the clutch cover to the gearbox housing.
■ Remove the safety clip from the end of the clutch above the gearbox housing and detach the cable from the clutch disengagement lever.
■ Push the shutdown lever back (e.g. metal rod) With the clutch disengaged in this manner, place it around the perimeter of the clutch pressure plate, at equal intervals, three buckles, which will lock the pressure plate.
■ Unscrew the pressure assembly from the flywheel and remove the clutch disc
■ Unscrew the fork fixing bolt from the clutch release lever and remove the pressed-in shaft sleeve of the release lever.
■ Pull the release lever up out of the housing and remove the forks
■ Remove the release bearing guide bushing bolts from the gearbox housing.
■ Check, if the O-ring on the guide sleeve is dirty. If it is dirty, it must be replaced, levering with a screwdriver.
New sealing ring, after filling the lip with grease, pushes onto the release bearing guide bush, using a suitable press-in tool.
During assembly work, remember about the correct tightening torques for threaded connections. The assembly of the clutch disc is in reverse order to that described above.
A new O-ring should be inserted into the housing groove under the guide bushing, free of grease and oil. After installing the release bearing and the forks, the clutch disc is inserted, with the long side of the hub facing the gearbox. Then, screw the pressure plate to the flywheel, in this way, align the semicircular notch on the edge of the platen with the colored mark on the handwheel. The spline on the clutch disc must be coated with grease beforehand. After lifting the clutch disc a bit, carefully insert the main shaft of the gearbox into its hole. Screw a cylinder screw into the end of this shaft and push the whole thing into the gear assembly as far as it will go. (using the special Opel-KM device 564 or a suitable tool). Place a new circlip on the shaft journal. By screwing the plug into the rear cover of the gearbox, its edge should be smeared with sealant. The cap may protrude from the inside of the lid by max. on 4 mm. Remove the clamps on the clutch pressure plate and screw the cover back on. Connect the pull rod and secure with the clip. Finally, adjust the clutch pedal setting.