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

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

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 .

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

Fig 1: Identifying Special Tools (11 9 260) And (11 9 265)

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Release screws and remove clutch from flywheel.

Installation note:

Clean flywheel and check for wear and damage.

Replace damaged flywheel.

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

Fig 2: Locating Flywheel Screws

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

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: Inserting Special Tool (21 2 180) Hooks In Self-Adjusting Clutch

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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: Identifying Special Tool (21 2 170)

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

Center clutch disc (1) with special tool 21 2 270 .

IMPORTANT: Install clutch disc in correct position.
Note designation for "engine side"/"transmission side".
Handle clutch disc with care. Do not touch surfaces of friction linings.

Fig 6: Identifying Center Clutch Disc With Special Tool (21 2 270)

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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: Fitting Clutch To Flywheel

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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: Releasing Spindle From Diaphragm Spring

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

Fig 9: Identifying Accompanying Screw

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Installing removed clutch with new clutch disc:

IMPORTANT: Before installing a used clutch with a new clutch disc, always reset adjusting 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 recesses of clutch.

Fig 11: Inserting Special Tool (21 2 180) Hooks In Self-Adjusting Clutch

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

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

Fig 12: Identifying Special Tool (21 2 170)

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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).

Adjusting 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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Center clutch disc (1) with special tool 21 2 270 .

IMPORTANT: Install clutch disc in correct position.
Note designation for "engine side"/"transmission side".
Handle clutch disc with care. Do not touch surfaces of friction linings.

Fig 14: Identifying Center Clutch Disc 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: Fitting Clutch To Flywheel

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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: Releasing Spindle From Diaphragm Spring

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

Fig 17: Identifying Accompanying Screw

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Installing new clutch

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

Center clutch disc (1) with special tool 21 2 270 .

IMPORTANT: Handle clutch disc with care. Do not touch surfaces of friction linings.
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.

Fig 18: Identifying Center Clutch Disc 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: Locating Clutch Dowel Pins

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Carefully unscrew locking element (1) clockwise or counterclockwise with SW14 Allen key (2).

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

Fig 20: Removing Clutch Plate Screw Using Special Tool

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

Fig 21: Identifying Accompanying Screw

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