21 21 500 Removing And Installing Or Replacing Clutch (SAC 228)

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Special tools required:

11 9 260 . See ENGINE- SPECIAL TOOLS (N52K) .

For the following special tools, see CLUTCH - SPECIAL TOOLS .

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 . See 23 00 017 REMOVING AND INSTALLING TRANSMISSION (GS6-17BZ) N51/N52/N52K/N53 .

Installation:

Screws must be replaced.

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

Identification SAC clutch (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 Pressure Spring

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Block flywheel with special tool 11 9 260 . See Fig 2.

Fig 2: Identifying Special Tools (11 9 260)

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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

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Remove clutch plate (1) from flywheel.

Clean flywheel, check for wear and damage.

Replace damaged flywheel . See 11 22 500 REMOVING AND INSTALLING/REPLACING FLYWHEEL (N52K) or 11 22 500 REMOVING AND INSTALLING OR REPLACING FLYWHEEL (N51) .

Check grooved ball bearing in crankshaft for ease of movement and tightness and if necessary replace grooved ball bearing.

Fig 4: Identifying 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 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). See Fig 6.

Fig 6: Identifying Sac Clutch And Special Tool

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

Fig 7: Locking Hooks Of Special Tool

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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 Tools (21 2 180) And Knurled Screws

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NOTE: Insert special tool 21 2 170 only in area of bores for dowel pins. See Fig 10.

Fig 9: Identifying Bores For Dowel Pins

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

Fig 10: Identifying Special Tools (21 2 170)

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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.

Center clutch plate (1) with special tool.

For the following special tools, see CLUTCH .

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 Clutch Plate And Special Tools

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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.

Tightening torque. See 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: Identifying Spindle And Diaphragm Spring

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Release knurled screw (1) and remove special tool 21 2 170 from SAC clutch. See Fig 15.

Fig 15: Identifying Special Tools (21 2 170)

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Release knurled screws (2) and remove special tool 21 2 180 from SAC clutch. See Fig 16.

Fig 16: Identifying Special Tools (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 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). See Fig 18.

Fig 18: Identifying Sac Clutch And Special Tool

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NOTE: Locking hooks (1) of special tool 21 2 180 must engage in openings in SAC clutch. See Fig 19.

Fig 19: Locking Hooks Of Special Tool

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NOTE: Insert special tool 21 2 170 only in area of bores for dowel pins. See Fig 20 and Fig 21 .

Fig 20: Identifying Bores For Dowel Pins

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

Fig 21: Identifying Special Tools (21 2 170)

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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). See Fig 22.

Fig 22: Identifying Special Tools (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. See Fig 23.

At same time tighten down knurled screws (2).

Adjustment ring of SAC clutch is now secured in new position.

Fig 23: Identifying Special Tools (21 2 180)

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

Fig 24: Identifying 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.

Center clutch plate (1) with special tool.

For the following special tools, see CLUTCH .

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 Clutch Plate And Special Tools

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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.

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

Fig 26: Identifying SAC Clutch And Dowel Pins

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

Fig 27: Identifying Spindle And Diaphragm Spring

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Release knurled screw (1) and remove special tool 21 2 170 from SAC clutch. See Fig 28.

Fig 28: Identifying Special Tools (21 2 170)

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Release knurled screws (2) and remove special tool 21 2 180 from SAC clutch. See Fig 29.

Fig 29: Identifying Special Tools (21 2 180)

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

Fig 30: Identifying Special Tool And Clutch Plate

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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 Transmission. For the following special tools, see CLUTCH .

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 Clutch Plate And Special Tools

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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 SAC Clutch Onto Dowel Pins

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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: Removing Locking Piece

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

Fig 34: Identifying Special Tool And Clutch Plate

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