Tutorial: Change clutch cable (Peugeot 306 1.9 L D – XUD engine)
This tutorial shows how to change a clutch on a 306 cable 1.9 L D model 1994 (XUD engine). Clutch cable will, therefore, a mechanism of automatic playing catch-up. This mechanism has become common on our vehicles for some time already.
Engage or disengage?
To avoid any confusion later, it should be noted immediately 2 points:
- Engaged: it is the State of the clutch to rest. The engine is then coupled to the gearbox. This is the case when the car is running (or that she sleeps in the garage).
- Disconnected: it is the State when you press the clutch pedal. The box is then more driven by the engine. This is the case during the change of speed.
How to test the clutch cable?
A clutch cable is not really testable. However, you can check the status of the cable. A cable tired, about to break, is usually frayed on the ends.
If the catch-up game mechanism is broken, you will have the impression of not being able to disengage. Therefore, you cannot shift gears without gnash the teeth of the gearbox (until you can't do nothing at all).
If the cable itself is broken, the clutch pedal will be blocked at the bottom and will no more rise. Similarly, you cannot of course shift gears.
How to test the clutch?
If you have a clutch problem, and you have not seen a problem on the clutch cable, you can always test the clutch in the following way:
- Tighten the hand brake.
- Disengage: Depress the clutch pedal
- Pass the second gear
- Slowly engage: gradually increase the clutch pedal
- Motor should stall before having completely reassembled the clutch pedal. This means that the clutch hangs again. The hand brake prevents the vehicle to move forward. The engine must therefore toil and stalling. If the clutch is worn, it will more hang enough and the engine will be not enough slowed to stall.
- Do not run the engine with Handbrake and speed past without disengaging the clutch. This would make that end to use your clutch. As soon as you see that the motor stalls, or not slowed not, disengage and remove the speed.
Composition of the clutch cable
Clutch cable consists of 4 elements ranging from the clutch pedal to the gearbox clutch rod.
- U-plug: it serves to connect the cable to the clutch pedal in the driver cockpit.
- Retrofit of automatic playing mechanism: the mechanism resembles a tube in which the clutch cable goes. It allows to always have the point of skating at the same place in automatic way.
- Intermediate block: plastic small rack in 2 parts which fixed the clutch cable on top of the gearbox
- Timing on the clutch Rod block: stop plastic and metal at the end of the clutch cable that hangs in the clutch to the gearbox rod.
'Origin' and 'repair' clutch cables
The original clutch cable may differ a little of a repair cable. This is seen mainly on the size and the catching up of automatic game clip. This is due to the fact that a cable can be adapted to several vehicles. The differences are generally minimal and repair cables come with the instructions.
Position of the clutch cable
The clutch cable connects the clutch rod, on the gearbox, to the clutch pedal, under the dash.
Without any disassembly, you can see the clutch cable, down, behind the battery compartment. The other end of the cable is visible under the air filter housing, near the clutch rod, on the gearbox.
The gearbox is located on the side front left of the engine. To access the intermediate support of the cable to the gear box, you may be forced to remove the battery as well as its support. Otherwise you will need to work a bit blind.
To access the cable side bracket, you will need to remove the fuse cover and the flexible vent air vent driver's side. If you slide apart this duct, open the hatch above the door fuse (small empty Pocket), to access at the junction of the duct and reconnect.
Clear the access to the gear box
This part is not mandatory, but in this case you will be working blind which is not practical. You may in addition to hurt you quite easily.
- Remove the set from the air filter and air intake to the intake manifold
Remove the battery. Beware, if you have a car radio with a code, need to enter this code after replacing the battery. If you do not know this, you will need to keep connecting the permanent 12V for the car radio.
Detach the housing at the rear of the battery compartment. This is the 306 preheating case. Do not disconnect. Remove the right of the battery compartment.
Remove the battery compartment
Unmount the plate under the battery compartment
Now, you can fully see the cable and its intermediate support on the gearbox.
Remove the clutch cable
Detach the cable the clutch rod
- At the level of the transmission rod, pull the cable stop towards the front of the vehicle
Then release the cable passing through the slot in the rod
Release the cable of the intermediate bracket that secures it to the gearbox. The sheath holds onto the surface with a small metal clip. Pull it out with a flat screwdriver to release.- Remove the plastic from the box by lifting it. It is just seated on it.
Detach the cable from the clutch pedal
In the engine compartment, on the wall of the cabin, under the master VAC, pull a little on the cable to twist out of the bodywork.
Inside the cabin, under the steering wheel, pass your finger along the clutch pedal back to the plug u of the clutch cable.- Then, rotate the plug u on its axis for the unclip.
In the engine compartment, pull out the hole under the VAC master clutch cable
Remount the clutch cable
- In the engine compartment, position the clutch cable through the body, under the master VAC brake.
- Go to the cockpit and connect the plug in U to the clutch pedal
- Go back in the engine compartment
- Connect the intermediate support of the cable on top of the gearbox. Get it from the back to the front of this recess on the box until you hear a small click.
- Bring all of the stop (metal + plastic) at the end of the cable
- Pull the stop forward passing the cable through the hole in the control box rod
- Release the stopper of the clutch cable on the control box rod
- Engage the mechanism of automatic playing catch-up. Attention, the procedure depends on the model of cable used. New cables are therefore supplied with a small leaflet explaining how toggle catching up (turn right and push upwards in my case).
- Disengage then some shots. And then test if the rates go well.
Replacing annexes parts
- Replace the back plate of the battery compartment
- Replace the battery compartment
- Reattach the housing of preheating on the back of the battery compartment
- Replace the battery
- Replace the air filter and air intake Assembly