Self-Adjusting Clutch (Sachs Version), Servicing

Self-adjusting clutch (Sachs version), servicing, 02X, 6-Speed Four-Wheel Drive M/T

CAUTION!
On this type of clutch the pressure plate and clutch plate can only be replaced together.

^ Identification
^ Select correct clutch plate and pressure plate according to engine code.





1 - Bolt -22 Nm-

2 - Pressure plate
^ Self-adjusting
^ Identification
^ Pressure plate and clutch plate can only be replaced together.
^ Check ends of diaphragm spring
^ Check spring connection and rivets
^ Check wire ring

3 - Clutch plate
^ Pressure plate and clutch plate can only be replaced together.
^ Installation position: Clutch lining must make full contact with flywheel
^ The marking "Getriebeseite" (transmission side), if provided, faces pressure plate/transmission.
^ If installed, coil springs (damper assembly) face pressure plate and transmission
^ Centralize

4 - Bolt for flywheel
^ Always replace
^ Observe instructions for removal
^ Bolt length: 22.5 mm; 60 Nm plus an additional 90° 1/4 turn
^ Bolt length: 43 mm; 60 Nm plus an additional 180° 1/2 turn

5 - Dual-mass flywheel
^ Ensure that dowel pins fit tightly
^ Contact surface for clutch lining must be free of grooves, oil and grease
^ Observe instructions for removal

6 - Needle bearing





Identification
Pressure plate with stop mechanism (position sensor) - arrow -.





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

Note:
^ Important: When performing repairs, always select the correct clutch pressure plate and clutch plate by checking engine code.





Checking spring connection and rivet
- Check spring connections - arrowsA - for damage and make sure riveted fastenings - arrowsB - are seated tightly.

Note:
^ Replace pressure plate if spring connections are broken or badly bent, or if riveted fastenings are loose.





Checking wire ring
- Check that wire ring in pressure plate - arrow - is not damaged. replace pressure plate if wire ring is broken.





Removing dual-mass flywheel

Note:
^ Do not use an impact wrench or pneumatic wrench to remove bolts - B -: this would severely damage the dual-mass flywheel. Bolts - B - must always be removed by hand.

- Rotate flywheel - A - so that bolts - B - are aligned centrally behind the holes - arrows -
- When removing bolts - B -, make sure the bolt heads do not contact the flywheel arrows because this would damage the flywheel when the bolts are turned further.