Clutch — removal (Peugeot 305)

1. Removing the clutch from the crankshaft requires the use of at least one special tool "Peugeot", which is a puller for the clutch hub (N 80.0206A). If the clutch is to be removed with the engine standing on the machine, you will also need a tool to fix the crankshaft pulley (N 8.0206 HZ) and an adapter from 1/2 inch to 23 mm. The puller is necessary in order to remove the clutch from the crankshaft cone with the engine removed from the machine, you are unlikely to be able to remove the clutch from the crankshaft using a conventional universal puller. With the engine on the machine, access to the clutch is very difficult, and to remove the pulley you will need a retainer and adapter, as well as a socket wrench and 41 mm open-end wrenches. If you do not have special tools, it is better to entrust the work of removing the clutch to a specialist.



2. Disconnect the negative cable from the battery and jack up and support the front of the machine. Engage handbrake.

3. To save yourself some extra work, install a nut from the clutch housing bolts under the cooling system thermostat. (see b/fig. 5.8). and fix it in place with a lump of plasticine.




4. Remove the following parts in the order shown in the figure.

• A. air inlet (from the air cleaner onwards (see chapter 3)
• b. generator (see chapter 10)
• V. upper and lower pulley brackets on which the fan/pump belt rests (see chapter 2)
• d. Fan/pump drive belt (see chapter2)
• e. Alternator drive belt (see chapter 10).

5. Without draining the coolant, disconnect the radiator from its mounts (see chapter 2) and move it towards the battery.



6. Support the left end of the engine with a jack, bringing it under the exhaust pipe support bracket.



7. Unscrew the fixing nuts of the generator regulator and, without disconnecting the wires from the regulator, move it to the side.


8. Remove the 4 nuts and washers securing the upper left engine support bracket and remove the bracket.

9. Using special tool 8.0206 HZ, block the crankshaft from rotating and unscrew the crankshaft pulley bolt. Remove bolt and pulley (see B / fig.5.11).



10. Loosen locknut and adjusting nut on clutch cable. Pull cable end out of clutch release lever (nuts and washers do not need to be removed from the cable).

11. Remove the clutch housing mounting bolts and remove the outer half of the crankcase and the clutch release lever. Remove release bearing.

12. Unscrew the hexagon bolt securing the sensor bracket to the TDC. at the bottom of the inner half of the clutch housing. Remove bracket with sensor. Do not touch the Phillips screw securing the sensor to the bracket (see photo).



13. Using a special puller 8.0206 A, remove the flywheel with the clutch from the crankshaft. They are secured by two half-rings that fit into a groove on the clutch centering sleeve and are held in place by the clutch. In order to disconnect the flywheel with the clutch from the crankshaft, considerable force is required. If required, the crankshaft can be kept from rotating by blocking the drive gear or flywheel.



14. Carefully pull out the flywheel with the clutch, being careful not to damage the cooling system hoses.