Peugeot 208 Clutch Replacement: Complete Guide to DIY and Professional Repair

Replacing the clutch on a Peugeot 208—especially models fitted with the 1.2 PureTech (EB2) engine—is one of those maintenance jobs that separates the casual DIY enthusiast from the serious car tinkerer. Whether you’re planning to tackle the task at home or simply want to understand what’s involved before visiting a mechanic, this detailed guide walks through every aspect of Peugeot 208 clutch replacement, from required tools to torque specs, with practical insights to ensure flawless results.

1. Introduction

The clutch is the critical link between your Peugeot 208’s engine and transmission, ensuring smooth gear changes and optimal power delivery. Over time, friction, heat, and wear degrade the clutch disc, pressure plate, and release bearing—leading to slipping, juddering, or difficulty shifting gears.

For the Peugeot 208 1.2 PureTech, clutch replacement involves separating the gearbox from the engine, cleaning the flywheel, and refitting a new clutch kit. With precision and care, this task can be performed at home using basic tools.

2. Signs Your Peugeot 208 Needs a Clutch Replacement

Before tearing down your transmission, look for clear indicators that the clutch system is failing:

• Slipping clutch under acceleration
• Burning smell during gear changes
• High clutch pedal engagement point
• Grinding or difficulty engaging gears
• Shuddering or vibration when taking off
• Soft or spongy clutch pedal feel

When these symptoms appear, inspect the clutch disc and pressure plate immediately to avoid further damage.

3. Tools and Equipment Required

You don’t need a full workshop—just the right essentials.

Estimated cost for tools: around $25–$40 if purchased new.

4. Safety Precautions

• Work on a flat, well-ventilated area.
• Always wear gloves to avoid cuts and chemical irritation.
• Use eye protection when brushing metal parts.
• Wear a mask when dealing with clutch dust—it’s often hazardous.
• Never work under an unsupported vehicle.

5. Preparing for the Job

1. Disconnect the battery to prevent electrical issues.
2. Lift the vehicle using a hydraulic jack and secure it with stands.
3. Remove the front wheels for better gearbox access.
4. Drain gearbox oil before detaching the transmission.
5. Remove the driveshafts from both sides—this step is crucial before gearbox removal.

6. Accessing the Clutch Assembly

The clutch is located between the engine and gearbox.
To reach it:

1. Disconnect the gear linkage cables.
2. Remove the starter motor (often bolts through the bell housing).
3. Unbolt the gearbox mount.
4. Support the engine with a hoist or floor jack.
5. Unbolt the gearbox bell housing from the engine block.

Once the gearbox is removed, you’ll see the flywheel and clutch assembly clearly.

7. Removing the Gearbox

Use care when separating the gearbox—never force it. If it sticks, recheck for hidden bolts or brackets.

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8. Cleaning and Inspecting the Flywheel

The clutch kit does not include a new flywheel, so inspect and clean it thoroughly:

• Brush off dirt and corrosion using a metallic brush.
• Wipe with degreaser or white spirit to eliminate oil and grease.
• Smooth the surface with grit 400 sandpaper for even friction.
• Check for cracks or excessive wear—replace the flywheel if damaged.

9. Installing the New Clutch Kit

A Peugeot 208 clutch kit typically includes:

• Clutch disc
• Pressure plate (clutch cover)
• Release bearing

Steps:

1. Wear new gloves to avoid contaminating friction surfaces.
2. Position the clutch disc against the flywheel, ensuring correct orientation.
3. Insert the clutch alignment tool through the disc’s center.
4. Mount the pressure plate and thread all bolts by hand first.
5. Tighten bolts in opposite sequence for even pressure distribution.

10. Aligning the Clutch Disc

The alignment tool is vital—without it, refitting the gearbox can be a nightmare.
If you don’t have one, use a deep socket or improvised dowel of similar size.

After tightening:

• Verify that the disc moves slightly when the tool is turned.
• Ensure the disc is perfectly centered within the flywheel and pressure plate.

11. Reassembling the Gearbox

1. Clean the bell housing and ensure the input shaft splines are free of dirt.
2. Apply a small amount of high-temperature grease to the input shaft splines.
3. Carefully guide the gearbox back into position—do not use force.
4. Once aligned, insert and tighten mounting bolts by hand first.
5. Refit the driveshafts, linkages, and mounts.
6. Refill gearbox oil and reconnect the battery.

12. Torque Specifications (1.2 PureTech EB2 Engine)

Always use thread-lock compound on the flywheel bolts and mark tightened bolts with a permanent marker.

13. Bleeding and Adjusting the Clutch

After installation:

1. Reconnect the clutch hydraulic line.
2. Bleed the clutch to remove trapped air.
3. Pump the pedal several times to check for consistent pressure.
4. Inspect for leaks around the master and slave cylinders.

If the pedal feels soft, continue bleeding until it firms up.

14. Common Mistakes to Avoid

• Touching the clutch disc with greasy hands.
• Forgetting to tighten bolts in the correct pattern.
• Not cleaning the flywheel surface.
• Skipping gearbox oil refill.
• Using incorrect torque settings.

Each of these can cause premature clutch failure or gearbox misalignment.

15. Cost of Peugeot 208 Clutch Replacement

DIY replacement can save up to 60% of total cost but requires mechanical confidence and time.

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16. Professional vs DIY Replacement

• DIY Advantages: Cost savings, hands-on learning, satisfaction.
• Professional Repair: Faster, warranty-backed, and safer for inexperienced owners.

If you lack a lift or clutch alignment tool, professional service may be the smarter option.

17. Final Checks and Test Drive

After reassembly:

1. Start the engine and check idle stability.
2. Press the clutch pedal—feel for smooth engagement.
3. Engage gears to confirm correct operation.
4. Perform a short test drive—verify that gear shifts are seamless and clutch bite point feels natural.

If you experience vibration, noise, or inconsistent engagement, recheck alignment and bolt torque.

18. FAQs

1. How long does a Peugeot 208 clutch last?
Typically 60,000–100,000 miles depending on driving style.

2. How long does it take to replace the clutch?
Around 4–6 hours for professionals; 8–10 hours for DIY mechanics.

3. Should I replace the flywheel as well?
Not mandatory unless the flywheel surface shows cracks or deep scoring.

4. What’s included in a Peugeot 208 clutch kit?
A clutch disc, pressure plate, and release bearing (no flywheel).

5. Can a slipping clutch damage the gearbox?
Yes. Prolonged slipping increases heat and stress on transmission components.

Final Thoughts

Replacing the clutch on a Peugeot 208 is entirely achievable with patience, precision, and the right tools. By following the correct torque sequences, maintaining cleanliness, and ensuring alignment, you can restore your 208’s gear shifts to factory-smooth operation while saving hundreds in repair costs.

For those with mechanical aptitude, this is one of the most rewarding DIY projects you can perform on your Peugeot.

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