21 21 500 Removing And Installing Or Replacing Clutch (SAC 240)

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Special tools required:

IMPORTANT: Do not clean self-adjusting clutch and flywheel with high pressure cleaner or washing machine as the proper function of adjustment unit and damping springs can no longer be guaranteed.
Clean friction surface only.
Check SAC clutch for wear and damage and replace if necessary.

Necessary preliminary tasks:

Remove TRANSMISSION .

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: Image shows new position of synchronizing keys.

Fig 1: Openings With Pressure Piece Of Adjustment Ring And Pressure Spring

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Lock flywheel with special tool 11 9 260 .

Fig 2: Locking Flywheel With Special Tool 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: SAC Clutch Bolts

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Installation note:

Screws must be replaced.

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

Remove clutch disc (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 .

Fig 4: Clutch Disc

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IMPORTANT: Always replace clutch discs fouled e.g. by oil, cleaning agent.

Check clutch disk for damage and friction rust in hub profile and replace if necessary.

Check clutch disc for wear:

Measure lining protrusion at lining rivets at closing head (A) in each case.

NOTE: Rivet connection

Closing head.
Swage head.

Replace clutch disc 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: Checking Clutch Disc For Wear

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Reinstalling removed SAC clutch and clutch disc:

Set SAC clutch (1) down on a clean surface.

Insert special tool 21 2 180 in SAC clutch (1).

Fig 6: Inserting 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 of SAC clutch.

Fig 7: Locking Hooks Of 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 Special Tool 21 2 180 Together At Handles

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NOTE: Fit special tool 21 2 170 only in area of bore holes for dowel pins.

Fig 9: Special Tool 21 2 170 Bore Holes Area

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

Fig 10: Tightening Down Knurled Screw On Special Tool 21 2 170

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

Fig 11: Screwing Spindle

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

Center clutch disc (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 2 200 GS6-37BZ; GS6-17BG

21 2 230 GS6-53DZ/BZ, GS6-45DZ

21 2 250 GS6-17BG

Fig 12: Centering Clutch Disc 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 and tighten down screws.

Tightening torque: 21 21 1AZ .

Fig 13: Fitting SAC Clutch On Flywheel

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Release spindle (1) until load is fully removed from diaphragm spring (2).

Fig 14: Releasing Spindle 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: Removing Special Tool 21 2 180 From SAC Clutch

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

Fig 17: Removing Special Tool From Clutch Disc With Aid Of Accompanying Screw

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Installing removed SAC clutch with new clutch disc:

IMPORTANT: Before installing an SAC clutch which has been in service with a new clutch disc: always reset adjusting ring in new position.

Set SAC clutch down on a clean surface.

Insert special tool 21 2 180 in SAC clutch (1).

Fig 18: Inserting 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 of SAC clutch.

Fig 19: Locking Hooks Of Special Tool 21 2 180

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NOTE: Fit special tool 21 2 170 only in area of bore holes for dowel pins.

Fig 20: Special Tool 21 2 170 Bore Holes Area

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

Fig 21: Tightening Down Knurled Screw On 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 Adjustment Ring Of SAC Clutch

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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 Special Tool 21 2 180 Together At Handles

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

Fig 24: Screwing Spindle

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

Center clutch disc (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

Fig 25: Centering Clutch Disc With Special Tool

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21 2 200 GS6-37BZ; GS6-17BG

21 2 230 GS6-53DZ, GS6-45DZ

21 2 250 GS6-17BG

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: Fitting SAC Clutch On Flywheel

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Release spindle (1) until load is fully removed from diaphragm spring (2).

Fig 27: Releasing Spindle 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: Removing Special Tool 21 2 180 From SAC Clutch

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

Fig 30: Removing Special Tool From Clutch Disc With Aid Of Accompanying Screw

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Installing new SAC clutch:

IMPORTANT: Handle clutch disk carefully, do not touch surfaces of friction pads.
Install clutch disc (1) in correct position.
Note designation for "engine side"/"transmission side" .
The CLUTCH DISENGAGEMENT MODULE contained in the new AT clutch set absolutely must be installed.

Center clutch disc (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 2 200 GS6-37BZ; GS6-17BG

21 2 230 GS6-53DZ, GS6-45DZ

21 2 250 GS6-17BG

Fig 31: Centering Clutch Disc With Special Tool

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

Tightening torque: 21 21 1AZ .

Fig 32: SAC 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 anticlockwise 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 Clockwise/Anticlockwise With Hexagon Socket Wrench SW14

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

Fig 34: Removing Special Tool From Clutch Disc With Aid Of Accompanying Screw

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