Tools and Materials:
- New clutch kit (disk, pressure plate, and release bearing)
- Transmission fluid
- Oil filter (if applicable)
- Oil filter wrench (if applicable)
- Funnel
- Jack
- Jack stands
- Socket set
- Wrench set
- Pliers
- Screwdriver
Instructions:
1. Prepare the vehicle. Park the vehicle on a level surface and turn off the engine. Engage the parking brake and chock the wheels to prevent the vehicle from rolling.
2. Remove the transmission. Raise the front of the vehicle using a jack and support it with jack stands. Remove the wheels and the undercarriage cover to access the transmission. Disconnect the shift linkages and exhaust system. Unbolt the transmission mount and remove the transmission bolts. Carefully lower the transmission and drain the transmission fluid into a suitable container.
3. Inspect the old clutch. Examine the old clutch disk for wear, cracks, or glazing. Check the pressure plate for damage and the release bearing for proper operation.
4. Install the new clutch disk. Place the new clutch disk into the flywheel. Make sure the disk is properly aligned and seated. Install the pressure plate and secure it with the pressure plate bolts.
5. Install the release bearing. Position the release bearing in the clutch fork and secure it with the release bearing retaining clip.
6. Reinstall the transmission. Carefully lift the transmission into position and align the input shaft with the clutch disk. Install the transmission bolts and tighten them to the specified torque. Reconnect the shift linkages and exhaust system.
7. Add transmission fluid. Use a funnel to add new transmission fluid to the transmission through the fill plug. Refill the transmission to the recommended level.
8. Reinstall the wheels and undercarriage cover. Reinstall the wheels and the undercarriage cover. Lower the vehicle from the jack stands.
9. Test the clutch. Start the engine and press the clutch pedal. Shift into gear and release the pedal slowly. The vehicle should move smoothly without any jerking or slipping.
It's important to follow the specific repair manual for your particular Vauxhall Vivaro model for accurate instructions and torque specifications.
