Clutch Release Mechanism, Servicing

Clutch release mechanism, servicing
1. Transmission
2. Intermediate piece
^ Replace if damaged
3. Shaft seal
^ For input shaft
^ Removing, Refer to Fig. 1
^ Installing, Refer to Fig. 2
^ Pressing-in depth (factory): 3.5 mm
^ Pressing-in depth (repairs): 4.5 mm
4. Guide sleeve
5. Bolt, 15 Nm
^ Qty.3
6. Clutch release lever
^ Removing, Refer to Fig. 3
^ Must engage in the lugs in intermediate piece when installed, Refer to Fig. 4
^ Before installing, coat contact surface of clutch slave cylinder push rod with a thin layer of copper grease, e.g. Z381 351 TE
7. Leaf spring
8. Bolt, 25 Nm
^ Self locking
^ Always replace
9. Release bearing
^ Do not wash out, wipe clean only
^ Replace noisy bearings
^ Retainer lugs on release bearing must engage in release lever
10. Clutch slave cylinder
^ Bleeding clutch system, Refer to Clutch System, Bleeding
^ Removing and installing, Refer to Clutch Slave Cylinder, Service and Repair
^ When installing, push on until the securing bolt can be fitted
11. Bolt, 20 Nm
^ Selflocking
^ Always replace
12. Bracket for hose/line assembly
^ Engage in clutch slave cylinder
13. Push rod
^ Coat contact surface of push rod with copper grease, e.g. Z 381351 TE





Fig. 1 Removing shaft seal for input shaft
- pry seal out carefully with a screwdriver.

Note: Do not damage contact surface of shaft seal on input shaft.





Fig. 2 Installing shaft seal for input shaft
- Pack space between sealing lip and dust lip of new seal for input shaft with multipurpose grease.
- Fit a thin protective hose tightly over input shaft splines.
- Drive on seal for input shaft.
^ Pressing-in depth when fitted at factory: 3.5 mm
^ Pressing-in depth after repair work: 4.5 mm
- Remove protective hose.





Fig. 3 Removing clutch release lever
- Loosen bolt -1-, remove leaf spring -2and press back detent (arrow).
- Remove clutch release lever -4- together with release bearing -3-.
- Disengage release bearing retainer lugs from release lever.





Fig. 4 Installing clutch release lever
- Before installing clutch release lever, coat contact surface for slave cylinder push rod with a thin layer of copper paste.
- Insert clutch release lever-A- into intermediate piece -C- and engage (detent -B- will come into view).
- Insert leaf spring, Refer to (-item 7).