Tom's Nile GTi6

[Toms306]

Very quick 'guide' to the clutch change - battery, ECU, battery box and battery tray out. Unplug everything on the nearside and get wiring out of the way (I use bungee cord). Remove airbox and piping. Remove TB for access to starter. Remove pin and arm from clutch fork. Unbolt starter. Remove clutch cable and lift reverse cable. Unbolt earths and brackets from box. Should look something like this -





Jack up, remove wheels, remove hub nuts (impact wrench ftw), remove pinch bolts and pop out lower BJs. Remove NS shaft. Remove 11mm nuts from intermediate bearing and knock shaft out. Remove speedo drive (easier to manoeuvre).



Loosen all gearbox bolts, 4 at the top and 2 underneath on the '6! Take the weight of the engine with a jack. Take the weight of the box with another jack. Remove the 18mm gearbox mount nut. Then the mount bracket 13mms. And the mount stud. Fully remove gearbox bolts. Carefully lower gearbox, adjusting engine jack where necessary.



Laugh at the state of your clutch (Sachs cover and LUK centre, presumably original!)



Remove clutch cover bolts - hex key needed on the '6, torx on the HDi and 13mm on the 1.8 iirc! Pry the clutch cover off its dowels.





Give the flywheel a squirt of brake cleaner to get rod off all this dust etc



Take a picture of the new clutch so your neighbours think you're mental



Bolt it up with a clutch aligner, 25Nm of torque.