Clutch pressure plate clutch three piece set PGK004N MCK2420D ADP153009 620308 suitable for Citroen logo

Pre-installation Preparation

1. Vehicle and Site Preparation

• Park the vehicle on a flat surface, engage the handbrake, and shift into first gear. Use a jack with supports to lift the front of the vehicle by approximately 30 cm, ensuring the front and rear heights of the vehicle are consistent. Meanwhile, support the engine with stools to maintain balance and prevent the engine from tilting during subsequent operations.

2. Tools and Accessories

• Prepare tools including socket wrenches (size 13, T40, etc.), hexagon socket wrench (size 5), long-nose pliers, drive shaft puller, clutch alignment tool, torque wrench, etc. Verify that the new clutch kit is intact, and prepare additional auxiliary materials such as transmission fluid, high-temperature resistant grease, and thread locker.

3. Preliminary Preprocessing

• Disconnect the battery power supply and remove the relevant screws from the left front wheel fender and battery bracket. Drain part of the transmission fluid (no need for complete drainage). Sequentially remove the shift cable ball joint, the three fixing screws of the shift bracket, and connecting components such as the lower control arm ball joint to free up space for transmission removal.

Disassembly of Core Components

1. Dismantle the Transmission System and Gearbox

• First, remove the small screws connecting the gearbox, leaving only one large screw fixed at the top and bottom. Then remove the three engine mounts (to prevent damage to the mounts). Support the gearbox with tools, unscrew the remaining fixing screws, and slowly lower the approximately 35 kg gearbox (≈70 jin) and place it stably.

2. Remove the Old Clutch Kit

• Use a T40 tool to unscrew the 6 screws around the pressure plate and remove the old pressure plate and clutch disc. Take out the old release bearing and check the surface condition of the flywheel. Thoroughly clean any oil stains or rust; if the flywheel is severely worn, grind it smooth.

Installation of the New Kit

1. Install the Release Bearing and Guide Sleeve

• Apply high-temperature resistant grease to the release bearing and the fork ball joint washer. Assemble the new release bearing with the clutch guide sleeve in place. Thread locker can be applied to enhance fixation—no additional grease is needed.

2. Fix the Clutch Disc and Pressure Plate

• Place the new clutch disc on the flywheel in the correct direction and use a clutch alignment tool to ensure it is centered. Align the mounting holes of the pressure plate with the flywheel and evenly tighten the pressure plate bolts. It is recommended to follow the manufacturer’s calibrated torque to avoid uneven force.

3. Reset the Gearbox Assembly

• Use an alignment tool to accurately reset the gearbox and sequentially reinstall the previously removed engine mounts, lower control arms, and other components. If the drive shaft is rusted and stuck during installation, remove the entire assembly for treatment. Ensure all connecting parts fit tightly during assembly.

Final Assembly and Commissioning

1. Reinstall External Components

• Sequentially reinstall the shift bracket, shift cable ball joint, clutch slave cylinder, and other components. After tightening all fixing screws, mark them to prevent missing any unfastened parts. Refill with compatible transmission fluid and check for leaks.

2. System Reset and Adjustment

• Reconnect the battery. Some models require relevant system initialization. Adjust the clutch pedal free travel to approximately 10-15 mm to ensure smooth pedal return.

3. Testing and Acceptance

• After starting the vehicle, observe that the clutch operates without abnormal noise. During a test drive, check that the clutch engages smoothly with no slipping or incomplete disengagement. After stopping the engine, recheck the transmission fluid level and all connecting parts to confirm no loosening or leaks. The installation is complete once all conditions are normal.

I. Core Safety Operation Precautions (Top Priority)

1. Vehicle and Site Safety

• After lifting the vehicle, it must be secured with professional supports (relying solely on a jack is prohibited). Ensure the front and rear heights of the vehicle are consistent to prevent tilting and slipping. Support the bottom of the engine with stable stools or an engine bracket to avoid engine imbalance and falling after transmission removal.

• The operating area must be spacious and dry, with no open flames (to avoid contact with flammable substances such as transmission fluid). When removing/installing the transmission (weighing approximately 35 kg / 70 jin), two people must operate collaboratively or use a hydraulic lifting tool. Manual handling by one person with brute force is prohibited to prevent crushing injuries.

2. Personnel and Tool Protection

• Wear non-slip gloves and safety goggles throughout the operation. Avoid hand scratches from sharp edges when disassembling components such as the drive shaft and transmission. When using tools like a drive shaft puller, ensure the tool is securely clamped to prevent slipping and injury.

• Inspect all tools for integrity in advance (e.g., torque wrench calibrated accurately, sockets free of stripped threads). Using non-standard tools as substitutes is prohibited (e.g., using a regular wrench to tighten T40-sized screws may cause thread stripping).

II. Key Pre-installation Preparation Precautions

1. Accessory and Auxiliary Material Compatibility

• Use only genuine Citroën/Peugeot three-piece clutch kits or model-compatible kits (verify that the clutch disc model and pressure plate specifications match the original vehicle, such as the LUK clutch kit for the Peugeot 308). Mixing accessories from different models is prohibited (differences in friction plate thickness and pressure plate pressure will cause abnormal engagement).

• Use dedicated auxiliary materials:

• Transmission fluid must meet the manufacturer’s specifications (e.g., ATF WS or MTF75W-80 commonly used for Peugeot models); regular engine oil is prohibited.

• High-temperature resistant grease must be clutch-specific (ordinary grease will melt at high temperatures and contaminate the clutch disc, causing slipping).

• Use medium-strength thread locker (e.g., Loctite 243); high-strength thread locker may cause difficulty in subsequent disassembly.

• References：
  

• The precautions for installing the clutch kit on Citroën and Peugeot models you previously obtained are not derived from a single specific official document or public source. Instead, they are a practical summary integrated from multiple types of information, including maintenance experience with corresponding Citroën and Peugeot models, installation specifications from auto parts maintenance platforms, and hands-on sharing from vehicle owners. The specific information sources are as follows:

• 1. Hands-on Sharing from Peugeot 308 Owners

• A post published by a Peugeot 308 owner on the PCauto Peugeot 308 Forum (detailing their DIY clutch three-piece set replacement) serves as an important reference for many practical details. For example:

• Supporting the engine with stools to maintain balance;

• Removing screws related to the left front wheel fender and battery bracket;

• Draining part of the transmission fluid instead of complete drainage;

• The pressure plate being secured with 6 T40 screws;

• The transmission weighing approximately 35 kg (≈70 jin);

• Removing the entire drive shaft assembly if it is rusted and stuck;

• Using thread locker to enhance fixation.

• These detailed operations are highly consistent with the hands-on content described in the post.

• 2. Installation and Accessory Specifications from Auto Parts Platforms

• Maintenance-related content about clutch three-piece sets for models such as the Citroën C5 Aircross and Citroën C5, published on Bangshou Auto Parts Network (a professional auto parts platform), provides the basis for accessory compatibility and partial installation standards in the precautions. For instance:

• The clutch pedal free travel of approximately 10-15 mm;

• Requirements to align the clutch disc during installation and evenly tighten the pressure plate bolts;

• The need to clean the flywheel surface.

• These requirements are consistent with the installation specifications mentioned on the platform. Additionally, the reference to compatible brand accessories such as LUK in the content aligns with the recommended aftermarket accessories on the platform.

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