Renault Peugeot DPO & AL4, '05-Later Clutch Plate Kit - cloudfront.net
T o r q ue C onverter Part s Instructions
Renault Peugeot DPO & AL4, '05-Later
Clutch Plate Kit Part No.
RE-CP-2K
• RE-CP-2 Clutch Plate • RE-RV-3 Rivets (5) • RE-FN-3 Rivet Fasteners (5) Associated Part RG-O-2 Piston Seal
Figure 1
Clamps Remove 4 OE Rivets
Figure 2
1. Dissassembly a. After the converter has been split in half, remove the piston plate. b. Use a drill press or a Bridgeport type milling machine with a .500" dia. two-or-four flute center cutting end mill. Note: Do not use a drill.
c. Make sure that the piston plate, damper assembly and front cover are all sandwiched together and clamped to the machine table (Figure 1). Clamps
8 Rivet Heads
Figure 3
Transfer Holes
4 Spring Fingers
d. Carefully machine flush the four OE rivet fasteners, removing as little material as possible off the piston plate. (Figure 1). e. Remove the piston plate and clamp the front cover back down (Figure 2). Machine flush the eight rivet heads holding the damper assembly to the front cover, removing as little material as possible from the damper assembly. Try not to bend. NOTE: After removing the damper assembly, do not machine off the rivet studs. They will be needed later when reassembling the damper assembly.
f. Carefully remove the old rivets from the damper spring fingers (do not bend the spring fingers). g. Using a .185" drill, enlarge the eight holes in the damper where it was attached to the front cover, providing clearance for reassembling (Figure 3).
©2013 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
RE-CP-2K-IN 06-28-13 Page 1
T o r q ue C onverter Part s Instructions
Clutch plate kit re-Cp-2k
1. Dissassembly (continued) h. Re-surface the front cover if necessary. i. Set the damper assembly back on the front cover, using the holes in the spring finger. Transfer hole locations to the front cover. Using a .500" diameter end mill, centered on the locating marks, plunge cut .059" to .079" deep into the cover for rivet head clearance (Figure 4). 2. Reassembly a. Install four rivets (Sonnax RE-RV-3) in damper assembly.
Figure 4
Clamp Clamp 4 Spot Faces
b. Locate damper assembly over old rivet studs on front cover, hold securely in place and weld the damper assembly to the front cover. Note: Use a "spatter block" on both parts. Grind weld if necessary and clean completely (Figure 5).
(4X)
.079" .059"
c. Add the seal (Sonnax RE-O-2), clutch and piston plate to the assembly. Note: You may have to bend the spring fingers outward to insure that the piston plate does not ride on the clutch plate when in its free state.
Figure 5
d. W ith the piston plate in place, add the four fasteners (Sonnax RE-FN-3). Press securely down on the piston plate using the recommended "Huck" riveter RE-MI-TL and fasten the assembly together. e. Finish rebuilding the converter. Note: To order "Huck" pneumatic riveter (Huck part no. 2025) and associated tooling (Huck part no. 991456), ask for Sonnax RE-MI-TL.
Weld together damper and front cover. Install four SONNAX rivets RE-RV-3 install before welding.
Install SONNAX seal RE-O-2 before rivet.
©2013 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
RE-CP-2K-IN 06-28-13 Page 2
Renault Peugeot DPO & AL4, '05-Later
Clutch Plate Kit Part No.
RE-CP-2K
• RE-CP-2 Clutch Plate • RE-RV-3 Rivets (5) • RE-FN-3 Rivet Fasteners (5) Associated Part RG-O-2 Piston Seal
Figure 1
Clamps Remove 4 OE Rivets
Figure 2
1. Dissassembly a. After the converter has been split in half, remove the piston plate. b. Use a drill press or a Bridgeport type milling machine with a .500" dia. two-or-four flute center cutting end mill. Note: Do not use a drill.
c. Make sure that the piston plate, damper assembly and front cover are all sandwiched together and clamped to the machine table (Figure 1). Clamps
8 Rivet Heads
Figure 3
Transfer Holes
4 Spring Fingers
d. Carefully machine flush the four OE rivet fasteners, removing as little material as possible off the piston plate. (Figure 1). e. Remove the piston plate and clamp the front cover back down (Figure 2). Machine flush the eight rivet heads holding the damper assembly to the front cover, removing as little material as possible from the damper assembly. Try not to bend. NOTE: After removing the damper assembly, do not machine off the rivet studs. They will be needed later when reassembling the damper assembly.
f. Carefully remove the old rivets from the damper spring fingers (do not bend the spring fingers). g. Using a .185" drill, enlarge the eight holes in the damper where it was attached to the front cover, providing clearance for reassembling (Figure 3).
©2013 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
RE-CP-2K-IN 06-28-13 Page 1
T o r q ue C onverter Part s Instructions
Clutch plate kit re-Cp-2k
1. Dissassembly (continued) h. Re-surface the front cover if necessary. i. Set the damper assembly back on the front cover, using the holes in the spring finger. Transfer hole locations to the front cover. Using a .500" diameter end mill, centered on the locating marks, plunge cut .059" to .079" deep into the cover for rivet head clearance (Figure 4). 2. Reassembly a. Install four rivets (Sonnax RE-RV-3) in damper assembly.
Figure 4
Clamp Clamp 4 Spot Faces
b. Locate damper assembly over old rivet studs on front cover, hold securely in place and weld the damper assembly to the front cover. Note: Use a "spatter block" on both parts. Grind weld if necessary and clean completely (Figure 5).
(4X)
.079" .059"
c. Add the seal (Sonnax RE-O-2), clutch and piston plate to the assembly. Note: You may have to bend the spring fingers outward to insure that the piston plate does not ride on the clutch plate when in its free state.
Figure 5
d. W ith the piston plate in place, add the four fasteners (Sonnax RE-FN-3). Press securely down on the piston plate using the recommended "Huck" riveter RE-MI-TL and fasten the assembly together. e. Finish rebuilding the converter. Note: To order "Huck" pneumatic riveter (Huck part no. 2025) and associated tooling (Huck part no. 991456), ask for Sonnax RE-MI-TL.
Weld together damper and front cover. Install four SONNAX rivets RE-RV-3 install before welding.
Install SONNAX seal RE-O-2 before rivet.
©2013 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
RE-CP-2K-IN 06-28-13 Page 2
