Clutch: Service and Repair
Pressure plate/clutch driven plate, replacing
Special tools: 999 5112, 999 5662, 999 5663, 999 5677
Note: To remove the transmission, see Transmission, removing.
Note: The illustrations show a self-adjusting clutch. Where there are differences, these are noted.
Removal
Blocking the flywheel
Use gear sector 999 5112.
Applies only to certain engine versions with self adjusting clutches
Secure the clutch automatic adjustment. Use counterhold 999 5677. Locate the counterhold.
Aligning the counterhold for automatic clutch adjustment
Applies only to certain engine versions with self adjusting clutches
The three pins on the counterhold lock the automatic adjustment.
Position the tool as illustrated.
Ensure that all the three pins go into the groove in front of the tensioner springs for the automatic adjuster.
Press the ring against the pressure plate. Pull out the counterhold springs. Secure the three hooks in the center holes of the outer edge.
Installing the compression tool
Install compression tool 999 5662, together with the conversion kit on the clutch. The tool is modified as described in the Tool Bulletin. Ensure that the hooks grip correctly, although without clamping the adjuster springs. Center the compression tool and tighten the screw to light contact against the diaphragm spring. At the same time, check that the hooks on the tool are in position.
Applies only to clutches without self adjustment:
Note the position of the handle with slots. Then screw in by not more than two turns.
Remove the clutch and clutch driven plate
Applies only to certain engine versions with self adjusting clutches:
Compress the clutch so that the automatic adjuster is not under load.
If the clutch is worn, the counterhold turns the automatic adjustment to the original position marking.
The marking consists of two stamped arrows.
Then continue to screw in the compression tool until the diaphragm spring has pressed the pressure plate to a free position.
A click can be heard when the clutch pressure plate snaps out.
Remove the clutch and the clutch driven plate.
Relieving the load from the clutch diaphragm spring
Note: Do not allow the diaphragm spring to be under load for a long period of time. Relieve the load as soon as possible. Leave the compression tool in position.
Applies only to certain engine versions with self adjusting clutches:
Note: Keep fingers away from the three clutch rivets when relieving a load or removing the compression tool. There is a risk of clamping injuries.
Checking the clutch
Wipe the clutch. Use a dry cloth.
Check carefully for over heating damage, cracking, scoring or other damage to the friction surface
Check that spring is not damaged or broken.
Checking the pressure plate for out-of-true
Wipe the pressure plate friction area clean.
Check any out-of-true carefully. Use a ruler and a feeler gauge. Out-of-true is permitted in one direction only.
Out-of-true must not exceed 0.2 mm. If out-of-true is greater, replace the clutch.
The clutch must be replaced as a complete unit.
Checking the clutch driven plate
Wipe off the clutch driven plate. Use a dry cloth.
The cloth must be free of oil and contaminants.
Check the clutch carefully for signs of wear, damage through overheating, cracking or other damage.
Note: The clutch driven plate must always be replaced if there are no radial ripples remaining on the friction coating. The clutch driven plate must also be changed if there is oil or grease on it.
Checking that there are no cracks or large scratches on the flywheel
To replace the flywheel, see Replacing the flywheel.
Installation
Installing the centering tool for the clutch driven plate
Use centering tool 999 5663. The drift is modified as described in the Tool Bulletin. The conversion kit is included.
Remove the cone from the centering tool.
Install the centering tool in the flywheel center as far in as possible.
Use a wrench as a counterhold. Tighten the outer socket so that the drift expander locks the centering tool.
Feel to see that the centering tool is secured in the crankshaft.
Installing the clutch driven plate
Caution: Turn the slightly longer part of the clutch driven plate hub in towards the flywheel. There is a marking on the clutch driven plate.
Install the cone on the centering tool. Tighten the cone (by hand). Secure the clutch driven plate.
Note: Tightening tools must not be used on the cone or damage may be caused to the clutch driven plate.
Installing the tools on the clutch
Install counterhold 999 5677.
Install the compression tool 999 5662. First tighten the center screw on the compression tool to light contact. Then compress the clutch.
Note: When the center screw comes into contact with the diaphragm spring, the screw should, for a loose clutch, be tightened a maximum of 4-4.5 turns.
Applies only to certain engine versions with self adjusting clutches:
Note: When the center screw comes into contact with the diaphragm spring, the screw should, for a loose clutch, be tightened 4.5-5 turns or until a clear click is heard.
Installing the clutch
Applies only to certain engine versions with self adjusting clutches:
Check that the clutch automatic adjustment is secured with counterhold 999 5677.
Applies to all clutch versions:
Install the clutch and locate the guide pins.
Check that the clutch is in contact with the flywheel all around its circumference.
Carefully tighten the six screws, crosswise, so that the clutch is guided up onto the guide pins and lies in contact all around with the flywheel. Tighten the screws crosswise. Tighten to 25 Nm.
Removing the tools
Screw out the center screw. Remove the compression tool.
Note: Applies only to certain engine versions with self adjusting clutches: Keep fingers away from the three clutch rivets when relieving a load or removing the compression tool. There is a risk of clamping injuries.
Applies to all clutch versions:
Remove the hooks. Remove the counterhold.
Remove the centering cone from the clutch driven plate.
Remove the socket. Tap the centering tool lightly with a rubber mallet so that the expander releases. Use a rubber mallet so that the threads are not damaged. Remove the centering tool.
Remove the flywheel gear sector. Check the flywheel.
Note: To install the transmission, see Transmission, installing.