21 21 500 Removing and installing/replacing clutch (SAC 240)

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Necessary preliminary tasks

move TRANSMISSION .

N54

Block flywheel with special tools 11 9 260 and 11 9 265.

Fig 1: Blocked Flywheel With Special Tool (11 9 260) And (11 9 265)

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Release screws and remove clutch from flywheel.

Installation:

Clean flywheel and check for wear and damage.

Replace damaged flywheel.

Fig 2: Locating Screws

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

Observe the following procedure when installing the removed clutch and clutch plate.

Insert special tool 21 2 180 in clutch.

Press special tool 21 2 180 together at handles (1) as far as it will go and tighten down knurled screws (2).

Adjustment ring of clutch is now secured in its original position (wear position).

Fig 3: Pressing Handles Using Special Tools (21 2 180)

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

Fig 4: Locking Hooks Using Special Tool (21 2 180)

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

Screw in spindle (2) until diaphragm spring (3) is tensioned on stop.

Fig 5: Fitting Special Tool (21 2 170) Onto Knurled Screw

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

Centre clutch plate (1) with special tool 21 2 270 .

IMPORTANT: Install clutch plate in correct position. Note designation for "engine side"/"transmission side".

Handle clutch plate with care. Do not touch surfaces of friction linings.

Fig 6: Identifying Centre Clutch Plate With Special Tool

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Fit clutch (1) to flywheel.

Tightening torque 21 21 1AZ .

NOTE: Clutch (1) must be secured by way of dowel pins (2).

Fig 7: Identifying Clutch And Dowel Pins

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Release spindle (1) until load is fully removed from diaphragm spring (2) Remove special tools 21 2 170 and 21 2 180 .

Fig 8: Removing Spindle From Diaphragm Spring

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

Fig 9: Identifying Special Tool From Clutch Plate

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Installing removed clutch with new clutch plate

IMPORTANT: Before installing a used clutch with a new clutch plate, always reset adjustment ring in new position.

Set clutch down on a clean surface.

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

Fig 10: 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 clutch.

Fig 11: Locking Special Tool (21 2 180) Hooks

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

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

Fig 12: Fitting Special Tool (21 2 170) Onto Knurled Screw

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

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 clutch is now secured in new position.

Screw in spindle (1) until diaphragm spring is tensioned on stop.

Fig 13: Turning Handles Using Special Tools (21 2 180)

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Centre clutch plate (1) with special tool 21 2 270 .

IMPORTANT: Install clutch plate in correct position.

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

Handle clutch plate with care. Do not touch surfaces of friction linings.

Fig 14: Identifying Centre Clutch Plate With Special Tool (21 2 270)

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Fit clutch (1) to flywheel.

Tightening torque 21 21 1AZ .

IMPORTANT: Clutch (1) must be secured by way of dowel pins (2).

Fig 15: Identifying Clutch And Dowel Pins

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

Remove special tools 21 2 170 and 21 2 180 .

Fig 16: Removing Spindle From Diaphragm Spring

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

Fig 17: Identifying Screw

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Installing new clutch

IMPORTANT: Locking piece may only be removed clutch is screwed down!

Centre clutch plate (1) with special tool 21 2 270 .

IMPORTANT: Install clutch plate in correct position.
Note designation for "engine side"/"transmission side".

Handle clutch plate with care. Do not touch surfaces of friction linings.

Fig 18: Identifying Centre Clutch Plate With Special Tool (21 2 270)

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Fit clutch to flywheel.

Tightening torque 21 21 1AZ .

IMPORTANT: Clutch must be secured by way of dowel pins (1).

Fig 19: Identifying Clutch And Dowel Pins

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

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

Fig 20: Removing Locking Piece Using Hexagon Socket Wrench 14 A/F

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

Fig 21: Identifying Screw

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