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

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

Necessary preliminary tasks:

Remove TRANSMISSION .

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: Locating Pressure Spring

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Block flywheel with special tool 11 9 260 Holder.

Fig 2: Identifying Flywheel With 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: Locating SAC Clutch Bolts

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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 for leaks and if necessary replace ROLLER 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).

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

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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 Using Special Tool (21 2 180)

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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: Pressing Handles Using Special Tools (21 2 180)

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

Fig 9: Identifying Bores For Dowel Pins

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

Fig 10: Identifying Special Tool (21 2 170)

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

Fig 11: Turning Spindle

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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

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 Mandrel

GS6-53DZ

21 2 250 Mandrel

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: 21 21 1AZ .

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 Device from SAC clutch.

Fig 15: Removing SAC Clutch Using Special Tools (21 2 170)

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

Fig 16: Removing SAC Clutch Using 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 Tools And Clutch Plate Screw

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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 SAC Clutch And Special Tool (21 2 180)

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

Fig 19: Locking Hooks Using Special Tool (21 2 180)

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

Fig 20: Identifying Bores For Dowel Pins

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

Fig 21: Identifying Special Tool (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).

Fig 22: Turning Handles Using 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.

At same time tighten down knurled screws (2).

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

Fig 23: Pressing Handles Using Special Tools (21 2 180)

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

Fig 24: Turning Spindle

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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

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 mandrel

GS6-53DZ

21 2 250 mandrel

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: 21 21 1AZ .

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 Device from SAC clutch.

Fig 28: Removing SAC Clutch Using Special Tools (21 2 170)

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

Fig 29: Removing SAC Clutch Using Special Tool (21 2 180)

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

Fig 30: Identifying Special Tools And Clutch Plate 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

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 mandrel

GS6-53DZ

21 2 250 mandrel

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: 21 21 1AZ .

Fig 32: Identifying Clutch And 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 Clutch Plate Screw Using Special Tool

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

Fig 34: Identifying Special Tools And Clutch Plate Screw

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