Dual Clutch Removal and Installation

Tools needed

DDC INSTALLER TOOL This is mandatory to install the new DDC - PN: DDCT-01

Tools needed

DDC REMOVER TOOL: This tool is mandatory to remove the old DDC PN: DDCT-02

Tools Needed

ACTUATOR ADJUSTER JIG This tool is mandatory to reset the DDC actuator without a diagnostic tool PN: DDCT-04

Dual Dry Clutch Removal

STEP 1 - Remove the gearbox using a hydraulic lift table.

Dual Dry Clutch Removal

STEP 2 - Place gearbox on a workbench in a stable horizontal position.

Dual Dry Clutch Removal

STEP 3 - Remove the snap ring from the upper hub of DDC package with the snap ring pliers.

Dual Dry Clutch Removal

STEP 4 - Remove manually the top hub of DDC package.

Dual Dry Clutch Removal

STEP 5 - Remove the 2nd snap ring from the shaft with a screwdriver.

Dual Dry Clutch Removal

STEP 6 - Mount DDC Remover (DDCT-02) on the DDC, the axe must be in contact with primary shaft and each leg must be placed below the cover plate.

Dual Dry Clutch Removal

STEP 7 - Screw it using a wrench (19) until DDC bearing is completely removed from the primary shaft.

Actuator Removal

STEP 1 - Remove the plastic fork cover fixed by two screws. Use flat wrench 12.

Actuator Removal

STEP 2 - Remove the 5 screws that fix the actuator to the gearbox .Use flat wrench 12.

Actuator Removal

STEP 3 - Remove manually the two forks fixed on the actuator

Actuator Removal

STEP 4 - Remove manually the two forks fixed on the actuator.

Disassembly/ Assembly Release System

STEP 1 - Remove the 3 screws that fix the forks to the gearbox. Use Allen wrench 5.

Disassembly/ Assembly Release System

STEP 2 - Remove both release bearings and 3 screws that fix the guide tube to the gearbox. Use Allen wrench 5.

Disassembly/ Assembly Release System

STEP 3 - Remove guide tube and clean gearbox housing.

Disassembly/ Assembly Release System

STEP 4 – Prepare to add the quantity of grease provided by Valeo in box.

Disassembly/ Assembly Release System

STEP 5 – Add the quantity of grease necessary in forks, bearings and spline shaft.

Disassembly/ Assembly Release System

STEP 6 - Tighten 3 screws (M6) to fix new guide tube to gearbox housing. Use Allen wrench 5 - Tightening torque 15Nm.

Disassembly/ Assembly Release System

STEP 7 - Tighten 3 screws (M6) to fix new forks to gearbox housing. Mount release bearing. Use Allen wrench 5- Tightening torque 15Nm: only fits in one position.

Disassembly/ Assembly Release System

STEP 8 - Check if the release bearings can slide correctly by acting manually on the dual fork .

ACTUATOR SETTINGS AND FITTING

STEP 1 - Fix the actuator on the actuator adjuster tooling (DDCT-03) and tighten 3 screws to fix it correctly.

ACTUATOR SETTINGS AND FITTING

STEP 2 - Hook the lever with the first cylinder and pull CAREFULLY it until feel the stop, push the ruler to the end and measure the distance : 59 mm.

ACTUATOR SETTINGS AND FITTING

STEP 3 – Hook the tooling with the second cylinder and pull CAREFULLY it until feel the stop end and measure the distance on the ruler: 32 mm.

ACTUATOR SETTINGS AND FITTING

STEP 4 - Push completely until stop end the cylinder and insert the actuator adjuster (DDCT-04) on the hole. The final length of both cylinders must be 72mm.

ACTUATOR SETTINGS AND FITTING

STEP 5 - Rotate the adjuster to get the correct length. 4 revolution will be 1mm of cylinder displacement. Rotations: Lever 1 : 72 mm – 59mm= 13mm * 4 = 52 tool turns. Lever 2 : 72 mm – 32mm = 40mm * 4 = 160 tool turns.

ACTUATOR SETTINGS AND FITTING

STEP 6 - Check that the final length is correct (72 mm). Hook the lever with the first cylinder and pull CAREFULLY it until feel the stop, push the ruler to the end and measure the distance : 72 mm. Repeat the operation for the 2nd cylinder.

ACTUATOR SETTINGS AND FITTING

STEP 7 - Mount the actuator on the gearbox and insert the cylinder on the forks manually.

ACTUATOR SETTINGS AND FITTING

STEP 8 - Tighten all the screws of the actuator on the gearbox . Use flat wrench 12. Tightening torque 25 Nm.

DUAL DRY CLUTCH ASSEMBLY

STEP 1 - Fit the DDC tool (DDCT-02) on the new DDC package. Each leg must be placed and ensure below the cover plate.

DUAL DRY CLUTCH ASSEMBLY

STEP 2 - Fit the DDC on the gearbox main shaft. Be very careful with the weight.

DUAL DRY CLUTCH ASSEMBLY

STEP 3 - Remove the DDC tool DDCT-02 and put the cylinder of the DDC installer tool (DDCT-01) on the main shaft (to push the central bearing).

DUAL DRY CLUTCH ASSEMBLY

STEP 4 - Place the complete DDC installer (DDCT-01) on the gearbox.

DUAL DRY CLUTCH ASSEMBLY

STEP 5 - Fix the DDC installer tool (DDCT-01) on the gearbox on 3 holes with original gearbox screws.

DUAL DRY CLUTCH ASSEMBLY

STEP 6 - Screw it using a wrench 19” until DDC is completely assembled . When the bearing reach its position, the DDC package will have free play.

DUAL DRY CLUTCH ASSEMBLY

STEP 7 - Mount the inner snap ring a pliers.

DUAL DRY CLUTCH ASSEMBLY

STEP 8 - Insert manually the hub on the DDC package.

FLYWHEEL REMOVAL AND FITTING

STEP 1 - Remove the 8 M10 bolts to extract the flywheel. Remember block the flywheel with a specific tool.

FLYWHEEL REMOVAL AND FITTING

STEP 2 - Inspect the crankshaft seal, if any presence of leak or damage . Repair it if needed before fit the new flywheel.

FLYWHEEL REMOVAL AND FITTING

STEP 3 - Position the new flywheel tightening manually the bolts M10x1.

FLYWHEEL REMOVAL AND FITTING

STEP 4 Apply progressive torque following a star sequence. Tightening torque 110Nm.