Clutch Replacement Instructions

This maintenance requires a good understanding of general mechanics and specific tools to perform the installation correctly. The clutch is the component that connects the engine to the wheels through the gearbox, thanks to frictional force: it is this force, the friction, that causes wear.

The kit generally includes the disc, pressure plate, and release bearing (in some cases, it may also be necessary to replace the flywheel). Start by disconnecting and removing the battery, the battery tray, and the airbox; then lift the vehicle on a ramp, remove the front right wheel, extract the safety pin, and unscrew the drive shaft retaining nut; remove the suspension wishbone and the links from the stabiliser bar, and slide the drive shaft out from the gearbox side (be careful of oil leaking from the gearbox).

Remove the gearbox mount and disconnect the intercooler pipe that runs under the gearbox; also remove the other drive shaft and drain the oil from the gearbox. Proceed to remove the engine mount, exhaust, and subframe (engine cradle) using a support jack.

At this point, you can proceed with the removal of the gearbox by disconnecting the sensor connectors, gear cables, and the clutch cable. Also remove the starter motor and complete the gearbox removal from the engine, supporting its weight with a strap.

Once the gearbox is removed, you can proceed with the clutch replacement by removing the pressure plate and then the disc itself. Clean everything and install the new gaskets and oil seals, then the bearings, flywheel, disc, and pressure plate using the appropriate alignment tool; then proceed in reverse to reassemble the gearbox.