Renault/Peugeot DP2 & AT8 Clutch Plate Kit - cloudfront.net
T O R Q UE C ONVERTER PART S Instructions
Renault/Peugeot DP2 & AT8
Clutch Plate Kit Part No.
RE-CP-3K
• Clutch Plate
with friction rings bonded to each side
• O-Ring • Rivets (5) • Fasteners ribbed (5)
Clutch Plate with friction rings bonded to each side O-Ring
Fasteners (5)
Rivets (5)
1. Disassembly a. Separate converter halves and remove the lip on center hub using a lathe. Lip diameter must be turned down to 2.500" (Figure 1). b. Clamp front cover and piston plate together to machine table (Figure 2). Use a drill press or Bridgeport-type milling machine with a 5/16" dia., two or four-flute center-cutting end mill to drill out piston plate rivets. (Figure 2).
Do not use a hand drill for this operation WARNING
c. Carefully machine the four OE rivets flush, using caution to remove as little material as possible from piston plate. d. Remove piston plate, clutch plate and center hub O-ring, then clamp front cover down. Remove the remains of the piston
Figure 1
Figure 2
Machine to 2.50" dia. Clamp
Clamp
Remove Four OE Rivets
©2014 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
RE-CP-3K 05-19-14 Page 1
T O R Q UE C ONVERTER PART S Instructions
CLUTCH PLATE KIT RE-CP-3K
1. Disassembly continued plate rivets from spring fingers by placing a 3/8" washer under finger and displacing rivet with a hammer and punch. e. Remove spring fingers from cover by machining the four OE rivet heads flush (Figure 3). Flip cover and place on machine table. Chuck a 7mm drill bit and move the cover until bit can center into the four larger dimpled holes on cover. Clamp cover down. f. Chuck a #9 (.196" dia.) bit and drill rivets out through cover
(Figure 4). Turn cover over and remove spring fingers, using a screwdriver to carefully pry them off the rivets. 2. Reassembly a. Machine four .500" x .020" counterbores into piston plate (Figure 5) for clearance with Sonnax rivet head during final assembly. b. Install Sonnax rivets and fasteners into OE spring fingers, oriented as shown (Figure 6).
Figure 3
Clamp
Clamp
Figure 4 Large Dimpled Holes (4x)
Use #9 (.196" dia.) bit to drill rivets through cover.
Machine four OE rivet heads flush.
Reference OE Spring Finger
Figure 5 OE Piston
Figure 6 Rivet OE Spring Finger
Machine four .500" dia. counterbores for clearance with Sonnax rivets. Fastener
©2014 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
RE-CP-3K 05-19-14 Page 2
T O R Q UE C ONVERTER PART S Instructions
CLUTCH PLATE KIT RE-CP-3K
c. Converters for 2.0L applications: Flip cover over and set finger/ rivet assemblies into the four holes previously drilled in cover (Figure 7). This will act as template for riveting fingers to piston plate in correct position.
2.0L Engine Cover
Converters for 1.6L applications: Cover cannot be used as template for riveting fingers correctly due to narrower placement of studs (Figure 8). A template fixture may be fashioned from a blank clamped to piston plate and drilled to correspond to cover holes (Figure 9).
Figure 7
Figure 9
Spring Finger Assembly
1.6L Mounting Fixture
Figure 8
2.0L Front Cover
©2014 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
1.6L Front Cover
RE-CP-3K 05-19-14 Page 3
T O R Q UE C ONVERTER PART S Instructions
CLUTCH PLATE KIT RE-CP-3K
d. Lay piston plate onto cover (2.0L) or template (1.6L), placing Sonnax rivets through plate holes. Peen rivets into piston plate (Figure 10). e. Install Sonnax center hub O-ring and Sonnax clutch plate. f. Install piston plate, guiding Sonnax fasteners through holes in cover (Figure 11).
g. Turn cover over and thread M5 nuts on two fasteners to draw piston plate into position against inside of cover (Figure 12). tack weld the two fasteners without nuts first. Next, remove nuts from the other two fasteners and tack weld. Cut off the remaining portions of all four fasteners and complete weld. h. Continue reassembly of converter.
Figure 10
Peen Sonnax rivets into piston plate, using cover or blank to align fingers.
Figure 11
Figure 12
M5 Nut Washer (not included)
M5 Nut Washer (not included)
©2014 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
Tack weld, cut off excess and complete weld.
Tighten nut to hold piston assembly against inner cover.
RE-CP-3K 05-19-14 Page 4
Renault/Peugeot DP2 & AT8
Clutch Plate Kit Part No.
RE-CP-3K
• Clutch Plate
with friction rings bonded to each side
• O-Ring • Rivets (5) • Fasteners ribbed (5)
Clutch Plate with friction rings bonded to each side O-Ring
Fasteners (5)
Rivets (5)
1. Disassembly a. Separate converter halves and remove the lip on center hub using a lathe. Lip diameter must be turned down to 2.500" (Figure 1). b. Clamp front cover and piston plate together to machine table (Figure 2). Use a drill press or Bridgeport-type milling machine with a 5/16" dia., two or four-flute center-cutting end mill to drill out piston plate rivets. (Figure 2).
Do not use a hand drill for this operation WARNING
c. Carefully machine the four OE rivets flush, using caution to remove as little material as possible from piston plate. d. Remove piston plate, clutch plate and center hub O-ring, then clamp front cover down. Remove the remains of the piston
Figure 1
Figure 2
Machine to 2.50" dia. Clamp
Clamp
Remove Four OE Rivets
©2014 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
RE-CP-3K 05-19-14 Page 1
T O R Q UE C ONVERTER PART S Instructions
CLUTCH PLATE KIT RE-CP-3K
1. Disassembly continued plate rivets from spring fingers by placing a 3/8" washer under finger and displacing rivet with a hammer and punch. e. Remove spring fingers from cover by machining the four OE rivet heads flush (Figure 3). Flip cover and place on machine table. Chuck a 7mm drill bit and move the cover until bit can center into the four larger dimpled holes on cover. Clamp cover down. f. Chuck a #9 (.196" dia.) bit and drill rivets out through cover
(Figure 4). Turn cover over and remove spring fingers, using a screwdriver to carefully pry them off the rivets. 2. Reassembly a. Machine four .500" x .020" counterbores into piston plate (Figure 5) for clearance with Sonnax rivet head during final assembly. b. Install Sonnax rivets and fasteners into OE spring fingers, oriented as shown (Figure 6).
Figure 3
Clamp
Clamp
Figure 4 Large Dimpled Holes (4x)
Use #9 (.196" dia.) bit to drill rivets through cover.
Machine four OE rivet heads flush.
Reference OE Spring Finger
Figure 5 OE Piston
Figure 6 Rivet OE Spring Finger
Machine four .500" dia. counterbores for clearance with Sonnax rivets. Fastener
©2014 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
RE-CP-3K 05-19-14 Page 2
T O R Q UE C ONVERTER PART S Instructions
CLUTCH PLATE KIT RE-CP-3K
c. Converters for 2.0L applications: Flip cover over and set finger/ rivet assemblies into the four holes previously drilled in cover (Figure 7). This will act as template for riveting fingers to piston plate in correct position.
2.0L Engine Cover
Converters for 1.6L applications: Cover cannot be used as template for riveting fingers correctly due to narrower placement of studs (Figure 8). A template fixture may be fashioned from a blank clamped to piston plate and drilled to correspond to cover holes (Figure 9).
Figure 7
Figure 9
Spring Finger Assembly
1.6L Mounting Fixture
Figure 8
2.0L Front Cover
©2014 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
1.6L Front Cover
RE-CP-3K 05-19-14 Page 3
T O R Q UE C ONVERTER PART S Instructions
CLUTCH PLATE KIT RE-CP-3K
d. Lay piston plate onto cover (2.0L) or template (1.6L), placing Sonnax rivets through plate holes. Peen rivets into piston plate (Figure 10). e. Install Sonnax center hub O-ring and Sonnax clutch plate. f. Install piston plate, guiding Sonnax fasteners through holes in cover (Figure 11).
g. Turn cover over and thread M5 nuts on two fasteners to draw piston plate into position against inside of cover (Figure 12). tack weld the two fasteners without nuts first. Next, remove nuts from the other two fasteners and tack weld. Cut off the remaining portions of all four fasteners and complete weld. h. Continue reassembly of converter.
Figure 10
Peen Sonnax rivets into piston plate, using cover or blank to align fingers.
Figure 11
Figure 12
M5 Nut Washer (not included)
M5 Nut Washer (not included)
©2014 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
Tack weld, cut off excess and complete weld.
Tighten nut to hold piston assembly against inner cover.
RE-CP-3K 05-19-14 Page 4
