Removing and Installing or Replacing Clutch

Remove Or Replacing Clutch

Special Tools Required
^ 11 2 170
^ 21 2 141
^ 21 2 170
^ 21 2 180

Necessary Preliminary Tasks:
^Remove Transmission
Please refer to Vehicle/ Transmission and Drivetrain/ Manual Transmission/Transaxle/ Service and Repair/ Procedures Service and Repair

SAC clutch (self-adjusting clutch): Identifying feature:
^ 3 recesses, each with one pressure piece (1) on the adjustment ring and one compression spring (2).

Note: Illustrations shows new position of pressure pieces.

6-cylinder engines: Block flywheel (1) with special tool 11 2 170.

Unfasten bolts 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 deep-groove ball bearing in crankshaft for ease of movement and leaks and if necessary replace 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 disk for wear: Measure lining protrusion at 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 (1) 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 together special tool 21 2 180 at handles (1) as far as ot will go and grip firmly.
At the 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 (1).

Screw in spindle (1) until diaphragm spring (2) is pretensioned on stop.

Important!
Handle clutch disk carefully, do not touch surface of friction pads.
Install clutch plate (1) in correct position.
Note designation for "engine side" / "transmission side".

Center clutch plate (1) with special tool 21 2 141 or 21 2142.

Important!
Pay attention to color marking when fitting SAC clutch with balance marking.
Position color marking (1) on dual-mass flywheel and color marking (2) on clutch pressure plate as closely as possible to each other.
Max. possible angle error: 60°

NOTE:
Fitting with balance marking from 04.2003

Fit SAC clutch (2) on flywheel.
Pay attention to dowel pins (2).
SAC clutch (1) must be secured by means way of dowel pins (2).
Insert screws and tighten down.

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 from clutch plate with aid of accompanying screw (1).

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 the 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 pretensioned up to stop.

zImportant!
Handle clutch plate with care, do not touch surfaces of friction linings.
Install clutch plate (1) in correct position.
Pay attention to text "engine end" / "transmission side".

Center clutch plate (1) with special tool 21 2 141 or 212142.

Fit SAC clutch (1) to flywheel.
Pay attention to dowel pins (2).
SAC clutch (1) must be secured by way of dowel pins (2).
Install retaining screws of SAC clutch and tighten down.

Release spindle (1) until strain 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 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 end" / "transmission side".

Center clutch plate (1) with special tool 21 2 141 or 21 2142.

Push SAC clutch onto dowel pins (1) located in flywheel and screw down.

Tightening torque, Clutch to flywheel.

All M8 8.8 Thread = 25 Nm.
All M8 10.9 Thread = 34 Nm.

Important! Locking piece (1) may only be removed when SAC clutch is screwed down!

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 is possible.

Withdraw special tool 21 2 141 or 21 2 142 with aid of accompanying screw (1) from clutch plate.