Clutch, Servicing

Notes:
^ Observe general repair instructions.
^ Replace clutch plates and pressure plates with damaged or loose rivets.
^ Select the correct clutch plate and pressure plate according to engine code:
^ Clean input shaft and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease G 000 100 to the splines. Then move clutch plate to and fro on input shaft unto hub moves freely on shaft. Excess grease must be removed.
^ Pressure plates have an anti-corrosion coating and are greased. Only the contact surface may be cleaned, otherwise the service life of the clutch will be considerably reduced.
^ If the clutch has burnt out, thoroughly clean the bellhousing, flywheel and puffs of the engine facing the transmission to reduce the smell of burnt linings.

- Remove transmission to work on the clutch.
A Colored marking on dual mass flywheel
^ If there is a white marking A-on dual mass flywheel it must coincide with white marking B- on pressure plate.
B -Colored marking on pressure plate
^ If there is a white marking -A-on dual mass flywheel it must coincide with white marking -B- on pressure plate.





1. Flywheel
^ Ensure centering pins are tightly seated
^ Contact surface for clutch lining must be free of scoring, oil and grease
^ Removing and installing
2. Bolt for flywheel 60 Nm + turn 180° further
^ Replace
3. Clutch plate
^ Installation position: Spring pack (coil springs) toward pressure plate and transmission clutch lining must make full contact with flywheel. Marking "Getriebeseite" (if provided) goes toward pressure plate and transmission
^ Do not grease
^ Clutch plate diameter
^ Centering see Fig. 1
^ Lightly grease splines
4. Pressure plate
^ Removing and installing see Fig. 1
^ Check ends of diaphragm spring see Fig. 2
^ Checking spring connection and riveted fastenings see Fig. 3
5. Bolt, 25 Nm
^ Loosen and tighten in stages and in diagonal sequence
6. Needle roller bearing
^ Removing and installing





Fig. 1 Centering clutch plate and removing and installing pressure plate
Required special tools and equipment
^ Flywheel retainer 3067
^ Mandrel 3176

- Position of clutch plate: spring pack (coil springs) or marking "Transmission side" toward pressure plate and transmission.
- Do not insert mounting bolts until clutch lining and contact surface of pressure plate make full contact with flywheel.
- Loosen and tighten bolts in small stages and in diagonal sequence to 25 Nm.
- Loosen and tighten bolts in stages and in diagonal sequence to 25 Nm.
- Reverse position of special tool 3067 when removing.
- Use mandrel 3176 to center clutch plate.





Fig. 2 Checking ends of the diaphragm spring
Wear up to half the thickness of the diaphragm spring is permitted

Note: When performing repairs, always match up clutch pressure plate and clutch plate by checking engine code.





Fig. 3 Checking spring connection and riveted fastenings
- Check spring connection between pressure plate and cover for cracks and make sure rivet fastenings are seated tightly.
- Replace clutches with damaged springs or loose riveted fastenings -arrows-.