21 21 500 Removing and installing or replacing clutch (SAC 228)

WARNING: This page is about a different variant/trim than selected.

Special tools required:

11 9 260
21 2 141
21 2 142
21 2 170
21 2 180
21 2 201
21 2 230
21 2 250

Necessary preliminary tasks:

Remove Transmission .

Installation:

Screws must be replaced.

Jointing torque and angle of rotation must be observed without fail.

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: Illustration shows new position of pressure pieces.

Fig 1: Identifying Adjustment Ring Pressure Pieces And Pressure Springs

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Block flywheel with special tool 11 9 260.

Fig 2: Using Special Tool (11 9 260) On Flywheel

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Unfasten bolts and remove SAC clutch from flywheel.

IMPORTANT: Do not use a special tool to detach SAC clutch from flywheel.

Fig 3: Identifying SAC Clutch Bolts On Flywheel

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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 tightness and if necessary replace grooved ball bearing. For instructions on replacing grooved ball bearing refer to 11 22 513 REPLACING ROLLER BEARING FOR DUALMASS FLYWHEEL .

Fig 4: Identifying Flywheel Clutch Plate

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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

Closing head
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.

Fig 5: Identifying Closing Head And Swage Head

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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:

Installation:

N52

Screws must be replaced.

Jointing torque and angle of rotation must be observed without fail.

Set SAC clutch (1) down on a clean surface. Install special tool 21 2 180 in SAC clutch (1).

Fig 6: Identifying Special Tool (21 2 180) In SAC Clutch

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NOTE: Locking hooks (1) of special tool 21 2 180 must engage in openings in SAC clutch.

Fig 7: Special Tool (21 2 180) Locking Hooks Engaging SAC Clutch Openings

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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.

Fig 8: Identifying Special Tool (21 2 180) Handles And SAC Clutch Knurled Screws

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NOTE: Insert special tool 21 2 170 only in area of bores for dowel pins.

Fig 9: Identifying SAC Clutch Bore Areas For Special Tool (21 2 170) Dowel Pins

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Fit special tool 21 2 170 and tighten down at knurled screw (1).

Fig 10: Identifying Special Tool (21 2 170) And Knurled Screw

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Screw in spindle (1) until diaphragm spring (2) is tensioned up to stop.

Fig 11: Identifying Spindle And Diaphragm Spring

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IMPORTANT: Handle clutch disk carefully, do not touch surfaces of friction pads.

Install clutch plate in correct position.

Note designation for "engine side" / "transmission side".

Installation:

N52

Screws must be replaced.

Jointing torque and angle of rotation must be observed without fail.

Centre clutch plate (1) with special tool.

SPECIAL TOOL SPECIFICATION

Special tool	Transmission
21 2 141	S6S 420G; S6S 560G; S5D 390Z
21 2 142	S5D 200G; S5D 250G; S5D 260Z; S5D 310Z
21 2 201	GS6-37BZ
21 2 230	GS6-53DZ
21 2 250	GS6-17BG

Fig 12: Identifying Centre Clutch Plate With Special Tool

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Fit SAC clutch (1) on flywheel.

Pay attention to dowel pins (2).

SAC clutch (1) must be secured by way of dowel pins (2).

Insert screws and tighten down.

For tightening torque refer to 21 21 1AZ in 21 21 CLUTCH DISC AND DRIVE PLATE .

Fig 13: Identifying SAC Clutch And Dowel Pins

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Release spindle (1) until tension is completely removed from diaphragm spring (2).

Fig 14: Removing From Diaphragm Spring

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Release knurled screw (1) and remove special tool 21 2 170 from SAC clutch.

Fig 15: Removing Special Tool (21 2 170) From SAC Clutch

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Release knurled screws (2) and remove special tool 21 2 180 from SAC clutch.

Fig 16: Identifying SAC Clutch Knurled Screws And Special Tool (21 2 180)

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

Fig 17: Identifying Special Tool And Accompanying Screw In Clutch Plate

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Installing removed SAC clutch with new clutch plate:

Installation:

N52

Screws must be replaced.

Jointing torque and angle of rotation must be observed without fail.

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).

Fig 18: Identifying Special Tool (21 2 180) In SAC Clutch

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NOTE: Locking hooks (1) of special tool 21 2 180 must engage in openings in SAC clutch.

Fig 19: Special Tool (21 2 180) Locking Hooks Engaged in SAC Clutch Openings

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NOTE: Insert special tool 21 2 170 only in area of bores for dowel pins.

Fig 20: Identifying Bores Areas For Special Tools (21 2 170) Dowel Pins

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Fit special tool 21 2 170 and tighten down at knurled screw (1).

Fig 21: Identifying Special Tool (21 2 170) And Knurled Screw

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Screw in spindle (1) until adjustment ring of SAC clutch (2) can be turned with special tool 21 2 180 at handles (3).

Fig 22: Identifying Spindle And Diaphragm Spring On Special Tool (21 2 170) With Special Tool (21 2 180)

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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.

Fig 23: Identifying Special Tool (21 2 180) Handles And Knurled Screws

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Screw in spindle (1) until diaphragm spring (2) is tensioned up to stop.

Fig 24: Identifying Special Tool (21 2 170) Spindle And Diaphragm Spring

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IMPORTANT: Handle clutch plate with care, do not touch surfaces of friction linings.

Install clutch plate in correct position.

Pay attention to text "engine end" / "transmission side".

Installation:

N52

Screws must be replaced.

Jointing torque and angle of rotation must be observed without fail.

Centre clutch plate (1) with special tool.

SPECIAL TOOL SPECIFICATION

Special tool	Transmission
21 2 141	S6S 420G; S6S 560G; S5D 390Z
21 2 142	S5D 200G; S5D 250G; S5D 260Z; S5D 310Z
21 2 201	GS6-37BZ
21 2 230	GS6-53DZ
21 2 250	GS6-17BG

Fig 25: Identifying Centre Clutch Plate With Special Tool

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Fit SAC clutch (1) on 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.

For tightening torque refer to 21 21 1AZ in 21 21 CLUTCH DISC AND DRIVE PLATE .

Fig 26: Identifying SAC Clutch, Flywheel And Dowel Pins

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Release spindle (1) until tension is completely removed from diaphragm spring (2).

Fig 27: Releasing Spindle To Remove Special Tool (21 2 170) From Diaphragm Spring

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Release knurled screw (1) and remove special tool 21 2 170 from SAC clutch.

Fig 28: Removing Special Tool (21 2 170) From SAC Clutch

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Release knurled screws (2) and remove special tool 21 2 180 from SAC clutch.

Fig 29: Releasing Special Tool (21 2 180) Knurled Screws From SAC Clutch

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

Fig 30: Removing Special Tool From Clutch Plate Using Accompanying Screw

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Installing new SAC clutch:

Installation:

N52

Screws must be replaced.

Jointing torque and angle of rotation must be observed without fail.

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

Centre clutch plate (1) with special tool.

SPECIAL TOOL SPECIFICATION

Special tool	Transmission
21 2 141	S6S 420G; S6S 560G; S5D 390Z
21 2 142	S5D 200G; S5D 250G; S5D 260Z; S5D 310Z
21 2 201	GS6-37BZ
21 2 230	GS6-53DZ
21 2 250	GS6-17BG

Fig 31: Identifying Centre Clutch Plate With Special Tool

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

Tightening torque, see 21 21 1AZ in 21 21 CLUTCH DISC AND DRIVE PLATE .

Fig 32: Identifying Dowel Pins And Screws In Flywheel

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IMPORTANT: Locking piece (1) may only be removed with SAC screw-mounted clutch!

Carefully unscrew locking piece (1) clockwise or counterclockwise with a hexagon socket wrench 14 A/F (2).

NOTE: A slight snapping of the plate spring while unscrewing is possible.

Fig 33: Identifying Clutch Locking Piece And Hexagon Socket Wrench 14 A/F

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

Fig 34: Identifying Special Tool From Clutch Plate

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