Replacing the clutch plate on a SMART ForTwo Cabrio involves several steps and requires a good understanding of automotive mechanics. click here for more details on the download manual…..
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Below is a detailed guide on how to perform this task, along with descriptions of the necessary components.
### Tools and Components Needed
#### Tools:
1. **Jack and Jack Stands**: To lift and secure the car safely.
2. **Socket Set**: Various sizes for removing bolts.
3. **Torque Wrench**: To ensure bolts are tightened to the specified torque.
4. **Screwdrivers**: Flathead and Phillips for removing clips and covers.
5. **Clutch Alignment Tool**: Helps position the new clutch plate accurately.
6. **Pliers**: For removing clips and retaining pins.
7. **Hammer**: For tapping stubborn components.
8. **Oil Drain Pan**: To catch any fluid during the process.
9. **Brake Cleaner**: To clean surfaces before installation.
10. **Shop Towels**: For cleaning and wiping excess fluids.
#### Components:
1. **Clutch Plate**: The primary component being replaced.
2. **Pressure Plate**: Holds the clutch plate against the flywheel.
3. **Release Bearing**: Engages and disengages the clutch.
4. **Flywheel**: Attached to the engine; the clutch plate presses against it.
5. **Clutch Fork**: Transfers movement from the clutch pedal to the release bearing.
### Step-by-Step Replacement Procedure
#### 1. Preparation
– **Safety First**: Ensure the vehicle is parked on a level surface, engage the parking brake, and disconnect the battery to avoid electrical shorts.
– **Gather Tools**: Make sure all tools and replacement parts are ready before starting.
#### 2. Lifting the Vehicle
– **Jack Up the Car**: Use a jack to lift the rear of the SMART ForTwo Cabrio. Secure it with jack stands to prevent it from falling.
#### 3. Remove the Transmission
– **Drain Transmission Fluid**: Place the oil drain pan under the transmission and remove the drain plug to let any fluid escape.
– **Disconnect Driveshafts**: Remove the bolts connecting the driveshafts to the transmission.
– **Remove Transmission Mount Bolts**: Locate and unbolt the transmission mounts.
– **Detach the Clutch Cable**: If applicable, disconnect the clutch cable from the clutch fork.
– **Remove the Transmission**: Carefully slide the transmission away from the engine. You may need to rotate it slightly to clear any obstructions.
#### 4. Access the Clutch Assembly
– **Remove the Pressure Plate Bolts**: With the transmission out, locate the pressure plate and remove the bolts securing it to the flywheel.
– **Take Off the Pressure Plate**: Gently pull the pressure plate away from the flywheel. Be cautious of the release bearing, which may come off with it.
– **Remove the Clutch Plate**: Slide the old clutch plate off the flywheel.
#### 5. inspect Components
– **Check Flywheel**: inspect the flywheel for wear or damage. If it’s uneven or scored, it may need resurfacing or replacement.
– **Inspect the Pressure Plate and Release Bearing**: look for signs of wear. If any components are damaged, replace them.
#### 6. Install New Components
– **Clean Surfaces**: Use brake cleaner to clean the flywheel
and pressure plate surfaces.
– **Install New Clutch Plate**: Align the new clutch plate with the dowels on the flywheel.
– **Use Clutch Alignment Tool**: Insert the alignment tool to keep the clutch plate centered while installing the pressure plate.
– **Install the Pressure Plate**: Position the pressure plate over the clutch plate and align it with the bolt holes. Hand-tighten the bolts initially.
– **Torque the Pressure Plate Bolts**: Using a torque wrench, tighten the bolts to the manufacturer’s specified torque settings in a crisscross pattern.
#### 7. Reassemble the Transmission
– **Reattach the Release Bearing**: Ensure it is seated correctly.
– **Slide the Transmission Back In**: Carefully align the transmission with the engine and slide it back into place. Make sure it engages with the input shaft of the transmission.
– **Reconnect Driveshafts and Mounts**: Reattach the driveshafts and secure the transmission mounts with bolts.
#### 8. Final Steps
– **Reconnect Clutch Cable**: If applicable, reconnect the clutch cable.
– **Fill Transmission Fluid**: Replace the drain plug and refill the transmission with the appropriate fluid.
– **Reconnect the Battery**: Once everything is in place, reconnect the battery.
– **Lower the Vehicle**: Carefully remove the jack stands and lower the vehicle back to the ground.
#### 9. Test
– **Test Drive**: Start the vehicle and take it for a short test drive. Check for any unusual noises and ensure the clutch engages and disengages smoothly.
### Conclusion
Replacing the clutch plate on a SMART ForTwo Cabrio can be a rewarding but challenging task. Ensure you follow safety precautions, and If at any point you feel unsure, consult a professional mechanic for assistance.
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