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REPXPERT Alistair Mason replaces the clutch assembly on a 2013 Kia Cee’d that has covered over 106,000 miles, with a diagnosis of clutch slip. With authorisation for the repair from the vehicle owner, Alistair helps the host workshop carry out the repair.
The Cee’d is Kia’s best-selling European car, mainly thanks to Kia’s generous seven-year warranty and competitive pricing. It has also proved very popular in the UK, so the chances of getting one in for repair are high.
The recommended labour time for this clutch replacement is 3.5 hours, with all installation instructions available via Schaeffler’s workshop knowledge portal – REPXPERT. As it is not too stressful a job, it offers a great repair opportunity for any for any independent garage.
Workshop equipment required
Note – before starting the install, make sure you have the locking wheel bolt key if needed.
With the vehicle placed on the lift, open the bonnet and remove the following items – top engine cover, air filter assembly, battery, engine control unit (Fig.1) and the battery carrier. This now gives good access to the gearbox, so the following components can now be disconnected; gear cables and cable bracket, reverse light switch multiplug (Fig.2) and the flywheel sensor at the back of the bell housing, before finally removing the top bell housing bolts.
With the vehicle still on the floor, slacken the front hub nuts and locking wheel bolts (if fitted), raise the ramp to waist height and then remove both the front wheels and hub nuts. With the front wheels removed, disconnect the retaining brackets for the front flexible brake pipes and the ABS sensors, remove the hub assembly bolts and ease the hub assembly out whilst supporting the CV joint so it can slide out of the hub (Fig.3).
Raise the vehicle lift to access the underside, remove the engine undertray and N/S splash guard, remove the gearbox drain plug and drain the gearbox oil. Whilst the oil is draining, disconnect the lower intercooler hose (Fig.4), remove the retaining bolt from the metal intercooler pipe and ease the pipe away from the gearbox to gain access to the lower bell housing.
Next, remove the small plate at the bottom of the bell housing and then remove the bottom bell housing bolt (Fig.5). Refit the gearbox oil drain plug and use a torque wrench to tighten it to the vehicle manufacture’s specifications, then remove the lower gearbox pendulum mounting and remove both driveshafts by levering out of the gearbox.
Note – it is advisable to slide a tube into the differential to support the internal gears and prevent them falling.
Next, remove the hydraulic slave cylinder from the gearbox, leaving the hydraulic pipe connected, before disconnecting the hydraulic pipe retaining bracket and earth strap on the front of the gearbox, then remove the lower bell housing bolts leaving two easily accessible bell housing bolts to support the gearbox until removal.
Support the engine with either an engine support or a second transmission jack, then remove the gearbox mounting, which is achieved by removing a blanking plate from the N/S inner wing before removing the two bolts (Fig.6). Once the mounting is disconnected, lower the engine and gearbox to ease gearbox removal, support the gearbox using a transmission jack, then remove the final bell housing bolts and ease the gearbox away from the engine. When the gearbox input shaft is clear from the clutch, lower the transmission jack and remove the gearbox from the vehicle.
CLUTCH REMOVAL AND INSTALLATION
Undo the nine clutch retaining bolts and remove the clutch assembly, at this point the clutch plate was examined and found to be at the end of its service life, as the lining had worn flush with the retaining rivets. Inspect the flywheel for any heat damage or cracks, then remove any glaze from the face using emery cloth before checking the back of the engine for any leaks that could contaminate the new clutch assembly (fix as required).
On to the gearbox and the release system; remove the release bearing and then the release fork, clean the bell housing area with clutch and brake dust cleaner then inspect the ball pivot and clutch release fork for any wear, as they must be replaced if worn. Carefully check the release bearing guide tube as this is prone to wear, which can restrict release bearing return and cause follow-on problems.
Lubricate release system pivot points with high melting point grease, mount the release fork on the ball pivot and then fit the new release bearing (Fig.7). Lightly apply high melting point grease onto the gearbox input shaft splines, mount the new clutch plate onto the input shaft splines and slide up to the guide tube and then remove, this will evenly distribute the grease whilst confirming the clutch is correct, before wiping off any excess grease.
With the gearbox now ready to be installed, the new clutch needs to be fitted. Using clutch and brake dust cleaner, degrease the flywheel surface and the new clutch pressure plate, ensuring the clutch plate is positioned correctly as indicated by the ‘Gearbox Side’ (or ‘Getriebe Seite’) markings. Using a clutch alignment tool, mount the new clutch onto the flywheel, tighten the bolts in an even and sequential process (Fig.8) before using a torque wrench to the vehicle manufacturer’s specifications.
Before fitting the gearbox, ensure both alignment dowels are still inserted on the engine and that all cables and brackets are clear so they will not get caught in the bell housing when installing the gearbox. Then, using the transmission jack, ease the gearbox into position and, once located onto the alignment dowels, secure in position with two bell housing bolts.
Refit in the reverse order of removal before refilling the gearbox with the correct specification oil. After reconnecting the battery, reset all effected consumers and always carry out a full road test to ensure a professional repair.
Information on Schaeffler products, fitting instructions, repair times and much more can be found on the REPXPERT garage portal at www.repxpert.co.uk, or on the REPXPERT app for iOS and Android devices. Using the app, simply scan the barcodes of the clutch components to find all product information and technical documents relating to the repair.
