1. Gather Tools and Parts:
- Safety gear (gloves, eye protection)
- Basic hand tools (wrenches, sockets, extensions, etc.)
- Clutch replacement kit (includes clutch assembly, release bearing, alignment tool)
- Flywheel locking pin
- Transmission oil (if necessary)
2. Prepare the Vehicle:
- Engage the parking brake.
- Raise and secure the front of the vehicle using jack stands.
- Remove the negative battery terminal.
3. Remove the Transmission:
- Disconnect the shift linkages.
- Remove any driveshaft(s) if necessary.
- Support the transmission with a transmission jack.
- Remove the transmission mount(s).
- Remove the transmission bolts and carefully separate the transmission from the engine.
4. Remove the Clutch:
- Insert the flywheel locking pin to prevent the engine from rotating.
- Remove the pressure plate bolts and carefully remove the pressure plate and clutch disc.
- Inspect the flywheel surface for any damage or grooves.
5. Install the New Clutch:
- Position the new clutch disc onto the flywheel, aligning the splines with the transmission input shaft.
- Check the alignment using a clutch alignment tool.
- Install the pressure plate and tighten the bolts gradually and evenly.
- Remove the flywheel locking pin.
6. Reinstall the Transmission:
- Carefully align the transmission input shaft with the clutch disc splines.
- Replace the transmission bolts and mount(s).
- Reinstall the driveshaft(s) if necessary.
- Connect the shift linkages.
7. Bleed the Clutch System:
- If the clutch system is hydraulic, bleed any air from the system following the specified procedure for the Peugeot 806 model.
8. Fill with Transmission Fluid (if applicable):
- Some Peugeot 806 models may have separate transmission fluid, refill if needed.
9. Test and Refill:
- Slowly lower the vehicle from jack stands.
- Refill the battery with the negative terminal.
- Test the clutch operation by depressing and releasing the clutch pedal.
10. Road Test:
- Take the Peugeot 806 for a road test to ensure proper clutch operation and shifting.
Remember, this is a summary, consult the vehicle-specific service manual or seek assistance from a qualified mechanic if you're unsure about any steps or procedures.
