Daewoo Nexia clutch replacement

Repair and replacement of the Daewoo Nexia clutch is a rather laborious operation that will require the removal of the gearbox. Daewoo Nexia clutch replacement is best done in a pit or overpass. Under the engine, it will be necessary to provide for the installation of a stop. For work, you will need not only a standard set of tools, but also a special mandrel for centering the clutch disc. Without this mandrel, it will not be possible to replace the clutch, since without proper alignment it simply will not be possible to insert the input shaft of the gearbox into the basket.

 

Volkswagen Passat b3 represents the third generation of the popular Trade Wind series. This model was produced in 1988, 1989, 1990, 1991, 1992 and 1993 with a family body and a sedan with gasoline and diesel engines.

There is a lot of work to be done to remove the Daewoo Nexia gearbox.

1. Remove the battery.

2. Having loosened the bolt of the terminal connection of the gearbox control rod with the drive input shaft, we remove the drive shaft from the rod hole.

3. Disconnect the reversing light switch harness connector.

4. Disconnect the vehicle speed sensor harness connector.

5. Remove the end of the hose from the clutch slave cylinder. At the same time, in order to prevent leakage of the working fluid from the clutch hydraulic tank, we tighten the clutch hydraulic hose.

6. Remove the left fender from the engine compartment.

7. From the bottom of the car with a “13” head, loosen the ten bolts securing the gearbox bottom cover and drain the oil into a replaced container.

8. Remove the front drive wheels.

9. Before unscrewing the bolts securing the clutch housing to the engine block, mark their location. This will simplify the subsequent installation of the gearbox, since the bolts are different in diameter and length of the rods.

10. At the top, the clutch housing is attached to the cylinder block with three bolts.

For clarity, we will show the location of the upper bolts of the clutch housing on the removed power unit.

11. From the side of the crankcase, with the “19” head, unscrew the two screws of the lower fastening of the clutch housing to the cylinder block, and with the “14” head, unscrew the three screws of the lower fastening of the clutch housing, the clutch housing to the crankcase.

12. From the side of the gearbox, with the “19” head, we unscrew one more screw of the lower fastening of the clutch housing to the cylinder block, and with the “14” head, we unscrew the screw of the lower fastening from the clutch housing to the engine oil pan.

13. Having replaced the emphasis under the gearbox, unscrew the two screws that secure the left bracket of the power unit to the side member.

14. Using the “14” head, unscrew the bolt securing the bracket for the left support of the power unit to the gearbox housing.

15. Through the windows of the bracket, unscrew two more bolts of their fastening.

16. Remove the support along with the pillow.

17. Replace with another bumper under the crankcase.

18. Disconnect the rear bracket of the power unit from the body.

19. Remove the gearbox from the engine and remove it together with the rear support of the power unit.

When removing or installing the gearbox, the gearbox input shaft must not rest on the petals of the clutch housing pressure spring, so as not to damage them.

To replace the Daewoo Nexia clutch, we carry out the following procedure.

Using the “11” head, unscrew the six bolts securing the clutch cover to the flywheel. We prevent the crankshaft from turning with a screwdriver inserted between the teeth of the flywheel and resting against the bolt inserted into the hole in the oil pan. We evenly unscrew the bolts, no more than one turn each, so as not to deform the diaphragm spring of the clutch housing. See photos of the process below.

We remove the casing (clutch basket) together with the driven disk.

When installing the clutch, we orient the driven disk with the protruding part of the hub towards the body and insert the centering mandrel into the hole in the driven disk.

We introduce the mandrel into the hole of the crankshaft and in this position we fix the clutch cover, evenly (one turn per pass) tightening the screws.

The centering mandrel for Nexia has the following dimensions, see the photo below. The cartridge can be machined on a lathe for metal, wood, plastic, or assembled from two cutting heads of a suitable diameter and length.

Some clutch kit manufacturers offer a free plastic mandrel and put it in the box with the new clutch.

With a certain desire, it is quite possible to replace the clutch with your own hands on a Daewoo Nexia. In addition, this operation with a moderate driving style should be carried out very rarely.