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

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Special tools required:

11 2 170
21 2 141
21 2 142
21 2 170
21 2 180
21 2 201
21 2 230
21 2 250

Necessary preliminary tasks:

Remove TRANSMISSION .

Installation:

Screws must be replaced.

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

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: Fig 1 shows new position of pressure pieces.

Fig 1: Pressure Piece And Pressure Spring

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Block flywheel with special tool 11 9 260.

Fig 2: Special Tool (11 9 260) And Flywheel

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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 Mounting Bolts

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Remove clutch plate (1) from flywheel.

Clean flywheel, check for wear and damage.

Replace (N52K) or (N51) damaged flywheel.

Check grooved ball bearing in crankshaft for ease of movement and tightness and if necessary replace grooved ball bearing.

Fig 4: Flywheel 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: Clutch Plate Rivet Closing And Swag Heads

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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: Special Tool (21 2 180) And SAC Clutch

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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, Special Tool (21 2 180) And Removal Direction

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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: Special Tool (21 2 180), Handles And Knurled Screws

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

Fig 9: Dowel Pins Bore Areas

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

Fig 10: Special Tool (21 2 170) And Tightening Screw

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

Fig 11: Spindle, Diaphragm Spring And Tightening Direction

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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 SPECIFICATIONS

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	GS6-53DZ
21 2 250	GS6-17BG

Fig 12: Special Tools And Clutch Plate

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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.

For tightening torque refer to 21 21 1AZ in 21 21 CLUTCH DISC AND DRIVE PLATE .

Fig 13: SAC Clutch, Dowel Pins And Special Tool

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Release spindle (1) until tension is completely removed from diaphragm spring (2).

Fig 14: Diaphragm Spring, Spindle And Release Direction

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

Fig 15: Special Tool (21 2 170, Knurled Screw And Removal Direction

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

Fig 16: Special Tool (21 2 180) And Knurled Screws

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

Fig 17: Accompanying Screw And Special Tools

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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: Special Tool (21 2 180) And SAC Clutch

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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, Special Tool (21 2 180) And Removal Direction

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

Fig 20: Dowel Pins Bores

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

Fig 21: Special Tool (21 2 170) And Knurled Screw

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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: Special Tool (21 2 180), SAC Clutch, Spindle, Handles And Installation Direction

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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: Special Tool (21 2 180), Handles And Knurled Screws

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

Fig 24: Installation Direction, Spindle And Diaphragm Spring

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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 SPECIFICATIONS

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	GS6-53DZ
21 2 250	GS6-17BG

Fig 25: Special Tools And Clutch Plate

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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.

For tightening torque refer to 21 21 1AZ in 21 21 CLUTCH DISC AND DRIVE PLATE .

Fig 26: SAC Clutch, Flywheel And Dowel Pins

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Release spindle (1) until tension is completely removed from diaphragm spring (2).

Fig 27: Spindle, Diaphragm Spring And Release Direction

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

Fig 28: Special Tool (21 2 170), Knurled Screw And Release Direction

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

Fig 29: Special Tool (21 2 180) And Knurled Screws

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

Fig 30: Accompanying Screw And Special Tools

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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 SPECIFICATIONS

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	GS6-53DZ
21 2 250	GS6-17BG

Fig 31: Clutch Plate And Special Tools

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

For tightening torque refer to 21 21 1AZ in 21 21 CLUTCH DISC AND DRIVE PLATE .

Fig 32: Flywheel Screw 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: Locking Piece, Hexagon Socket Wrench 14 A/F And Removal Direction

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

Fig 34: Special Tool, Accompanying Screw And Clutch Plate

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