21 21 500 Removing and installing/replacing clutch (SAC 240) - N20

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 .

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: Locating Pressure Piece Of Adjustment Ring And Pressure Spring

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Lock flywheel with special tool 11 9 260 .

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.
Replace screws.

Fig 3: Locating SAC Clutch From Flywheel Screws

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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: Identifying 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:

Place SAC clutch (1) on a clean support.

Insert 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 of SAC clutch.

Fig 7: Inserting Special Tool (21 2 180) Hooks In Self-Adjusting Clutch

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Press special tool 21 2 180 together at handles (1) up to the limit position.

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

Fig 9: 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.

Fig 10: Locating Dowel Pins Bore Holes

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Screw in spindle (1) until diaphragm spring (2) is pretensioned at limit position.

Fig 11: Turning Spindle

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

Center clutch disc (1) with special tool.

Special tool Transmission

21 2 230 GS6-45BZ

21 2 250 GS6-17BG

Fig 12: Identifying Center Clutch Disc 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 and tighten down screws.

Installation note:

Use new screws.

Tightening torque: 21 21 1AZ .

Fig 13: Identifying SAC Clutch And Dowel Pins

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

Fig 14: Releasing Spindle And Diaphragm Spring

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

Fig 15: Releasing Knurled Screw

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

Fig 16: Identifying Knurled Screws

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

Fig 17: Identifying Special Tools And Clutch Disc 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.

Place SAC clutch on a clean support.

Insert 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 of SAC clutch.

Fig 19: 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).

Fig 20: 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.

Fig 21: Locating Dowel Pins Bore Holes

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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) up to the limit position.

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 pretensioned at limit position.

Fig 24: Turning Spindle

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

Center clutch disc (1) with special tool.

Special tool Transmission

21 2 230 GS6-45BZ

21 2 250 GS6-17BG

Fig 25: Identifying Center Clutch Disc 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.

NOTE: Use new screws.

Tightening torque: 21 21 1AZ .

Fig 26: Identifying SAC Clutch And Dowel Pins

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

Fig 27: Releasing Spindle And Diaphragm Spring

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

Fig 28: Releasing Knurled Screw

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

Fig 29: Identifying Knurled Screws

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

Fig 30: Identifying Special Tools And Clutch Disc Screw

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Installing new SAC clutch:

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 OPERATOR MODULE located in the new AT clutch set must be installed.

Center clutch disc (1) with special tool.

Special tool	Transmission
21 2 230	GS6-45BZ
21 2 250	GS6-17BG

Fig 31: Identifying Center Clutch Disc And Special Tools

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

Installation note:

Use new screws.

Tightening torque 21 21 1AZ .

Fig 32: Locating SAC Clutch Screws

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IMPORTANT: Stop (1) may only be removed with SAC clutch screw-mounted.

Carefully unscrew stop (1) with a hexagon socket wrench 14 AF (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 disc with aid of accompanying screw (1).

Fig 34: Identifying Special Tools And Clutch Disc Screw

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