Clutch — removal (Peugeot 305)

1. Removing the clutch from the crankshaft requires the use of at least one special Peugeot tool, which is a clutch hub puller (N 80.0206A). If the clutch is to be removed with the engine still on the vehicle, a crankshaft pulley locking tool will also be required (N 8.0206 HZ) and a 1/2-inch to 23 mm adapter. A puller is needed to remove the clutch from the crankshaft cone with the engine removed from the car; you'll likely be unable to remove the clutch from the crankshaft using a standard universal puller. With the engine in the car, access to the clutch is very difficult, and to remove the pulley, you'll need a locking tool and adapter, as well as a socket wrench and 41mm open-end wrenches. If you don't have the necessary tools, it's best to leave the clutch removal job to a professional.



2. Disconnect the negative cable from the battery and jack up and support the front of the car. Apply the handbrake.

3. To save yourself from unnecessary work, install a nut from the clutch housing bolts under the cooling system thermostat. (see B/Figure 5.8). and fix it in place with a lump of plasticine.





4. Remove the following parts in the order shown in the figure.

• a. air intake duct (from the air cleaner onwards (see chapter 3)
• b. generator (see chapter 10)
• in. brackets of the upper and lower pulleys on which the fan/pump belt is located (see chapter 2)
• g. Fan/pump drive belt (see chapter 2)
• d. Generator drive belt (see chapter 10).

5. Without draining the coolant, disconnect the radiator from its mountings (see chapter 2) and move it towards the battery.



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6. Support the left end of the engine with a jack, placing it under the exhaust pipe support bracket.



7. Unscrew the fastening nuts of the generator regulator and, without disconnecting the wires from the regulator, move it to the side.



8. Unscrew the 4 nuts and washers securing the upper left engine support bracket and remove the bracket.

9. Using special tool 8.0206 HZ, block the crankshaft from rotating and unscrew the crankshaft pulley bolt. Remove the bolt and pulley (see B/ Figure 5.11).



10. Loosen the lock nut and adjusting nut on the clutch cable. Pull the cable end out of the clutch release lever (there is no need to remove the nuts and washers from the cable).

11. Loosen the clutch housing mounting bolts and remove the outer half of the housing and the clutch release lever. Remove the release bearing.

12. Remove the hex bolt securing the TDC sensor bracket to the bottom of the inner half of the clutch housing. Remove the bracket together with the sensor. Do not touch the Phillips screw that secures the sensor to the bracket (see photo).



13. Using special puller 8.0206 A, remove the flywheel with clutch from the crankshaft. They are secured by two half rings that sit in a groove on the clutch centering sleeve and are held in place by the coupling. It will take considerable force to disengage the flywheel and clutch from the crankshaft. If necessary, the crankshaft can be held from rotating by blocking the pinion gear or flywheel.





14. Carefully remove the flywheel with the clutch, being careful not to damage the cooling system hoses.