Removal and Replacement
21 21 500 Removing and installing or replacing clutch (SAC 240 / 4 cyl. M47TU/T2 only, 6, 8 cyl.)
Special tools required
- 11 2 070
- 11 2 170
- 21 2 141
- 21 2 142
- 21 2 170
- 21 2 180
- 21 2 201
- 21 2 230
Necessary preliminary tasks:
Remove transmission Service and Repair
Note: Depending on the model, the dual-mass flywheel must also be replaced together with the clutch. See note in Electronic Parts Catalogue
Identification SAC clutch dia. 240 mm (Self Adjusting Clutch):
3 openings each with a pressure piece (1) of adjustment ring and a pressure spring (2).
Note: Illustrations shows new position of pressure pieces.
4- and 6-cylinder engines:
Block flywheel (1) with special tool 11 2 170.
8-cylinder engines:
Block flywheel with special tool 11 2 070.
Release screws and remove SAC clutch from flywheel.
Important! Do not use a special tool to detach SAC clutch from flywheel.
Remove clutch plate (1) from flywheel.
Clean flywheel, check for wear and damage.
Replace damaged flywheel.
Check grooved ball bearing in crankshaft for ease of movement and leaks and if necessary replace grooved ball bearing.
Important! Always replace clutch plates fouled, e.g. by oil, cleaning agent.
Check clutch plate for damage and friction rust in hub profile and replace if necessary.
Check clutch plate for wear:
Measure lining protrusion on lining rivets at closing head (A) in each case.
Note: Rivet connection
a) Closing head
b) Swage head
Replace clutch plate if lining protrusion at closing head (A) is less than 1 mm.
Push clutch disk onto the cleaned transmission input shaft and check for easy movability.
Important! Do not clean SAC clutch with high-pressure cleaner or washing machine as this may impair function of adjustment unit.
Clean friction surface only.
Check SAC clutch for wear and damage and replace if necessary.
Reinstalling removed SAC clutch and clutch plate:
Set SAC clutch down on a clean surface.
Install special tool 21 2 180 in SAC clutch (1).
Note: Locking hooks (1) of special tool 21 2 180 must engage in openings in SAC clutch.
Press special tool 21 2 180 together at handles (1) as far as it will go and grip firmly.
At same time tighten down knurled screws (2).
Adjustment ring of SAC clutch is now secured in its original position (wear position).
Important! Do not reset adjustment ring to new position.
Note: Insert special tool 21 2 170 only in area of bores for dowel pins.
Fit special tool 21 2 170 and tighten down at knurled screw
Screw in spindle (1) until diaphragm spring (2) is tensioned up to stop.
Important! Handle clutch plate with care, do not touch surfaces of friction linings.
Install clutch plate (1) in correct position.
Pay attention to text "engine side" / "transmission side".
Center clutch plate (1) with special tool
Special tool / Transmission
21 2 141 S6S 420G; S6S 560G; S5D 390Z
21 2 142 S5% 200G; S5D 250G; S5D 260Z; S5D 310Z
2 21 201 GS6-37BZ
21 2 230 GS6-53DZ
Fit SAC clutch (1) to flywheel.
Pay attention to dowel pins (2).
SAC clutch (1) must be secured by way of dowel pins (2).
Insert screws and tighten down.
Tightening torque, 21 21 1AZ
Release spindle (1) until tension is completely removed from diaphragm spring (2).
Release knurled screw (1) and remove special tool 21 2 170 from SAC clutch.
Release knurled screws (2) and remove special tool 21 2 180 from SAC clutch.
Withdraw special tool 21 2 141 or 21 2 142 with aid of accompanying screw (1) from clutch plate.
Installing removed SAC clutch with new clutch plate:
Important!: Before installing an SAC clutch which has been in service with a new clutch plate: always reset adjustment ring in new position.
Set SAC clutch down on a clean surface.
Install special tool 21 2 180 in SAC clutch (1).
Note: Locking hooks (1) of special tool 21 2 180 must engage in openings in SAC clutch.
Note: Insert special tool 21 2 170 only in area of bores for dowel pins.
Fit special tool 21 2 170 and tighten down at knurled screw (1).
Screw in spindle (1) until adjustment ring of SAC clutch (2) can be turned with special tool 21 2 180 at handles (3).
Press special tool 21 2 180 together at handles (3) as far as it will go and grip firmly.
At same time tighten down knurled screws (2).
Adjustment ring of SAC clutch is now secured in new position.
Screw in spindle (1) until diaphragm spring (2) is tensioned up to stop.
Important!:Handle clutch plate with care, do not touch surfaces of friction linings.
Install clutch plate (1) in correct position.
Pay attention to text "engine side" / "transmission side".
Center clutch plate (1) with special tool
Special tool / Transmission
21 2 141 S6S 420G; S6S 560G; S5D 390Z
21 2 142 S5% 200G; S5D 250G; S5D 260Z; S5D 310Z
2 21 201 GS6-37BZ
21 2 230 GS6-53DZ
Fit SAC clutch (1) on flywheel.
Pay attention to dowel pins (2).
SAC clutch (1) must be secured by means of dowel pins (2).
Install retaining screws of SAC clutch and tighten down.
Tightening torque, 21 21 1AZ.
Release spindle (1) until tension is completely removed from diaphragm spring (2).
Release knurled screw (1) and remove special tool 21 2 170 from SAC clutch.
Release knurled screws (2) and remove special tool 21 2 180 from SAC clutch.
Withdraw special tool from clutch plate with aid of accompanying screw (1)
Installing new SAC:
Important: Handle clutch plate with care, do not touch surfaces of friction linings.
Install clutch plate (1) in correct position.
Pay attention to text "engine side" / "transmission side".
Center clutch plate (1) with special tool
Special tool / Transmission
21 2 141 S6S 420G; S6S 560G; S5D 390Z
21 2 142 S5% 200G; S5D 250G; S5D 260Z; S5D 310Z
2 21 201 GS6-37BZ
21 2 230 GS6-53DZ
Push SAC clutch onto dowel pins (1) located in flywheel and screw down.
Tightening torque, 21 21 1AZ
Important! Locking piece (1) may only be removed SAC screw-mounted clutch!
Carefully unscrew locking piece (1) clockwise or counterclockwise with a hexagon socket screw key 14 A/F (2).
Note: A slight snapping of the plate spring while unscrewing possible.
Withdraw special tool (1) from clutch plate with aid of accompanying screw (2) .