9.1. Coupling

General information

Fig. 9.1. An arrangement of elements of coupling on the car: 1 – coupling switching off lever; 2 – coupling switching off fork; 3 – coupling switching off bearing; 4 – a coupling casing assembled with a press disk; 5 – the conducted clutch plate; 6 – coupling switching off cable; 7 – coupling pedal; 8 – spring

On the cars equipped with the mechanical transmission dry one-disk coupling of diaphragm type (fig. 9.1) is used. Coupling drive hummock.

Fig. 9.11. Use of the hammer and a mandrel for installation of the needle bearing: And =25–28 mm

The gap between the needle bearing and a face surface of a bent shaft (distance And in fig. 9.11) makes
2,5–2,8 mm.

Moments of an inhaling, N • m
Bolt of fastening of the lever of switching off of coupling and fork..... 11
Bolts of fastening of a press disk to a flywheel..... 22–27
Nut of fastening of a shaft of the drive of wheels to a nave..... 160–240
Bolts of fastening of a flywheel..... 98–105
Nut of fastening of the stabilizer of cross stability..... 12–18
Bolts of fastening of a rotary fist to the shock-absorber..... 95–119
Bolts of fastening of a rotary fist to the spherical hinge..... 44–55
Nut of fastening of a wheel..... 90–120

 Coupling work check
Before performance of any operations with coupling it is necessary to execute several control operations to define whether there is a malfunction in coupling.
At the working engine and the included brake press a coupling pedal, without bringing it about 125 mm to the lower limit of the course of a pedal, and several times move the gear shifting lever back and forth. If transfers switch smoothly, so coupling works normally. If gear shifting is complicated, so coupling does not take away completely press a clutch plate and it is necessary to check draft.
Examine coupling pedal plugs on existence of wear and reliability of fastening.

Coupling pedal
For simplification of access remove an overlay of the dashboard and an air duct under the dashboard.

Fig. 9.2. Elements of fastening of a pedal of coupling: 1, 4 – plugs; 2 – bolt and nut; 3 – laying; 5 – pin; 6 – spring nest; 7 – auxiliary spring; 8 – coupling pedal; 9 – overlay of a pedal; 10, 16 – brackets; 11 – washer; 12 – flat washer; 13 – draft; 14 – nut; 15 – auxiliary saddle; 17 – spring washer; 18 – flat washer

Remove a clip and disconnect the top end of draft of a pedal of coupling (fig. 9.2).
Turn out a coupling bolt of a pedal and a nut, disconnect a cable of coupling and remove a pedal and assembly of draft from the car.
Before installation plentifully grease the plug of a pedal and a hook for a cable with lubricant on a lithium basis.
Correctly arrange a pedal, screw a coupling bolt and a nut and connect a coupling cable.
Connect draft of a pedal.
Check height of installation and a free wheeling of a pedal of coupling, if necessary adjust them.
Adjust length of an auxiliary spring, turning a nut on draft, so far the distance between a nest of a spring and an auxiliary saddle will not be in limits of 335-127 mm.
Establish an air duct.

Coupling drive cable

Fig. 9.3. Elements of fastening of a cable of the drive of coupling: 1 – lock-nut and adjusting nut; 2 – flat washer; 3 – roller; 4 – screw and strip of a bracket; 5 – nuts; 6 – laying of a suspension bracket; 7 – coupling drive cable

In a motor compartment turn off a lock-nut, an adjusting nut, remove a washer from the end of a cable and get a cable from the squeezing lever (fig. 9.3).
Extend a cable from a suspension bracket arm on the transmission.
Remove a strip of a bracket and an arm of fastening of a cable. Turn off nuts of fastening of a cable to a partition of a motor compartment.
In interior of the car for simplification of access remove an overlay of the dashboard and an air duct under the dashboard
Disconnect a cable from a pedal of coupling and take it from the car.
Before installation grease the surfaces of contact of a roller and the squeezing lever.
Insert a cable through a partition of a motor compartment and connect it to a coupling pedal. Screw the nuts fixing a cable to a partition of a motor compartment.
Insert a cable in squeezing the lever and establish a strip of a bracket and an arm.
Establish a washer and screw an adjusting nut and a lock-nut.
Adjust a coupling pedal gap.
Establish an air duct and an overlay of the dashboard.

Coupling repair
Remove the transmission.
Mark the provision of a press disk on a flywheel that at assembly it could be established in a starting position.
Use the special tool for alignment or the screw-driver handle for support of a clutch plate during removal of a press disk.
Using the special tool or the screw-driver, for teeths of a gear wreath of a flywheel block it from a provorachivaniye.
Gradually on diagonal weaken coupling fastening bolts assembled, turning each bolt half way until it is terminated springs and bolts can be unscrewed manually.

Fig. 9.4. Arrangement of elements of coupling: 1 – transmission; 2 – casing of coupling with a press disk; 3 – the conducted clutch plate; 4 – flywheel; 5 – coupling switching off bearing

Remove press a disk, supporting the conducted disk that it did not drop out (fig. 9.4).
Accurately handle the conducted clutch plate, observing precautionary measures not to concern surfaces of slips, and take it aside.

Fig. 9.5. Removal of the bearing of switching off of coupling

Disconnect a returnable spring from a coupling switching off fork hook, turn squeezing the lever and remove the bearing of switching off of coupling (fig. 9.5).
Turn out a bolt of fastening of a fork of switching off of coupling and remove a fork and the lever assembled.
Visual check
The electric vacuum cleaner or pure fabric clear a coupling casing of dust. Do not use compressed air as to inhale the dust containing asbestos it is unhealthy.
Examine press a disk on existence of traces of damage and wear of a spring of a diaphragm, scratches, zadir or coloring change (points to an overheat) surfaces, be convinced of lack of traces of damage or deformation of a casing. Insignificant defects of a surface of friction can be removed with a fine-grained emery paper, but press the disk should be replaced new in case of any doubts concerning its state.
Examine a flywheel surface on existence of uneven contact with the conducted clutch plate that indicates the wrong installation or damage of a diaphragm spring of coupling. Check a surface for existence of prigar, furrows, cracks or other signs of wear. If necessary remove a flywheel and process it on the machine for restoration of a surface. Polishing of a surface of a flywheel can be executed a fine-grained emery paper.

Fig. 9.6. Measurement of wear of frictional overlays of the conducted clutch plate

Examine frictional overlays of the conducted clutch plate on pollution existence by oil, lubricant or any other substance and if necessary replace the conducted disk. Check the conducted disk for wear, having measured distance from a rivet head to a slip surface. Replace a disk if wear of frictional slips reached the extreme value shown in fig. 9.6.
Examine the conducted clutch plate on existence of deformation, wear, weakening of rivets and springs, damage of shliyets of a nave. Temporarily establish the conducted clutch plate on a main shaft of the transmission and check smoothness of landing, lack of jags and wear of shliyets. If there are doubts concerning a condition of the conducted clutch plate, replace it.

Fig. 9.7. Check of smoothness of rotation of the bearing of switching off of coupling

Fig. 9.8. Check of sliding of the bearing of switching off of coupling on primary to a transmission shaft

Check the bearing of switching off of coupling for existence of wear and be convinced that it rotates smoothly, without extraneous noise and easily slides on primary to a shaft of the transmission (fig. 9.7, 9.8). Except for cases of very small run of the car, replacement of the bearing by new every time when coupling is removed is recommended.
Examine a coupling casing, the lever of switching off of coupling and a returnable spring on existence of wear, cracks, deformations, damages and on fatigue of metal, replacing elements as required.

Fig. 9.9. Check of smoothness of rotation of the needle bearing in an end face of a bent shaft

Fig. 9.10. Use of an inertial stripper for removal of the needle bearing

Check the needle bearing in an end face of a bent shaft to be convinced that it rotates easily and smoothly under the influence of effort only of your finger (fig. 9.9). In case of need replace the bearing, removing it an inertial stripper and establishing new in an opening of a bent shaft by means of a mandrel or a piece of a tube of the corresponding diameter and the hammer (fig. 9.10). Before installation grease the new bearing and at installation you watch the control distance given on fig. 9.11.
At installation new the conducted disk or a press clutch plate remove from them anticorrosive protection.
At installation of the conducted disk you watch that on its frictional slips even the insignificant amount of oil did not get. Therefore before installation by pure rags wipe a privalochny surface of a flywheel and a surface of a press disk, establish the conducted disk by clean hands.
Before installation grease the bearing of switching off of coupling, a vent of a main shaft and vent of the conducted clutch plate with lubricant on the basis of Moly paste. Be careful to prevent hit of lubricant on the surface of friction of a clutch plate, a flywheel and a press disk.
Hold the conducted clutch plate by means of the special aligning tool or a round core, establish coupling assembled, combining openings in a casing of coupling with the directing flywheel pins. At repeated installation of earlier removed press clutch plate check that the tags put before removal were combined.
Tighten coupling fastening bolts so that the conducted clutch plate was pressed, but at the same time could move in the parties.
Using a special mandrel or an old main shaft of the transmission, center a clutch plate concerning a flywheel.

If the conducted clutch plate is not centered, then it will be impossible to install the transmission.

After centering of the conducted disk gradually on diagonal tighten bolts of fastening of a casing of coupling the required moment.
Take a mandrel from the conducted disk.
Install the coupling switching off lever, a coupling switching off fork, a spring and the bearing of switching off of coupling.
Install the transmission.