Preparation:
1. Park the vehicle on a level surface, engage the parking brake, and turn off the engine.
2. Gather the necessary tools and parts, including the new clutch kit (which typically includes a clutch disc, pressure plate, and release bearing), transmission fluid, a transmission jack, and various hand tools.
Step 1: Remove the Transmission:
1. Disconnect the negative terminal of the battery to prevent any electrical accidents.
2. Remove the air filter assembly and any other components that may obstruct access to the transmission.
3. Disconnect the gear shift linkage from the transmission.
4. Detach any electrical connectors or sensors connected to the transmission.
5. Use a transmission jack or a suitable support to safely support the transmission.
6. Remove the bolts that secure the transmission to the engine.
7. Carefully lower the transmission, ensuring that it doesn't drop suddenly and cause damage.
Step 2: Inspect and Prepare the Flywheel:
1. Inspect the flywheel for any damage, cracks, or uneven wear. If necessary, have the flywheel resurfaced or replaced.
2. Clean the flywheel surface thoroughly using a wire brush and a degreaser to ensure proper contact with the new clutch.
Step 3: Install the New Clutch:
1. Remove the old clutch disc and pressure plate from the flywheel and inspect the release bearing for any signs of wear or damage. Replace if necessary.
2. Align the new clutch disc's splines with the input shaft of the transmission and carefully slide it onto the shaft.
3. Position the new pressure plate over the clutch disc and align it with the flywheel.
4. Evenly tighten the bolts that secure the pressure plate to the flywheel in a star pattern to prevent warping.
Step 4: Reinstall the Transmission:
1. Carefully lift the transmission back into position, ensuring that the input shaft aligns smoothly with the clutch disc.
2. Reinstall the transmission bolts and tighten them securely.
3. Reattach the gear shift linkage and any electrical connectors or sensors that were previously disconnected.
4. Reinstall the air filter assembly and other components that were removed during disassembly.
Step 5: Bleed the Clutch:
1. Locate the clutch master cylinder and the slave cylinder.
2. Open the bleeder screw on the slave cylinder and attach a clear hose to it.
3. Have someone depress the clutch pedal while you open the bleeder screw to allow air and old fluid to escape. Close the bleeder screw when the fluid becomes free of air bubbles.
4. Repeat this process until you have clear fluid coming out of the bleeder screw.
Step 6: Refill the Transmission Fluid:
1. Remove the transmission fill plug and top up the transmission fluid to the recommended level using a suitable funnel and the appropriate fluid specified by the manufacturer.
Step 7: Test the Clutch:
1. Start the engine and allow it to warm up.
2. Gently press the clutch pedal and shift into first gear. If the vehicle moves forward without any slipping, the clutch should be properly installed.
Remember, this is just a general overview of the steps involved, and the actual process may vary slightly depending on the exact model and year of your Peugeot 306. If you're not comfortable performing this repair yourself, it's best to consult with a qualified mechanic or auto repair shop.
