Removing and installing or replacing clutch (Cooper)

Special tools required: 

• 11 9 811
• 11 9 265
• 21 2 170
• 2 288 165
• 2 358 471

Preliminary work needed: 

• Remove TRANSMISSION .

Removal: 

Block flywheel with Torx screw (1) and special tools 11 9 811 and 11 9 265.

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Loosen 3 screws, in order to fit special tool 21 2 170 with the pressure plate 2 288 165.

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Fit special tool 21 2 170 with the pressure plate 2 288 165 and tighten down at knurled screw (1).

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Screw in the spindle (2) until the diaphragm spring (1) is preloaded and the clutch disk is free of tension.

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Loosen the remaining 3 screws and remove the clutch with clutch disc from the flywheel.

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Check the clutch disc for damage and contact corrosion in the hub profile and replace if necessary.

Check clutch disc for wear: 

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

1. Closing head
2. Swage head

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Replace clutch disc with the clutch 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.

Clean friction surface only.

Check clutch for wear and damage and replace if necessary.

Installation (reinstalling removed clutch and clutch disc): 

Center clutch disc (1) with special tool 2 358 471.

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Fit clutch (2) together with special tool to the flywheel.

Pay attention to dowel pins (1).

Clutch (2) must be secured using dowel pins (1).

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Insert 3 screws and tighten.

Part:  Replace screws.

Tightening torque 21 21 1AZ .

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Release spindle (2) until diaphragm spring (1) is completely relieved.

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

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Insert 3 screws and tighten.

Part:  Replace screws.

Tightening torque 21 21 1AZ .

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Withdraw special tool 2 358 471 from clutch disc with aid of accompanying screw.

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Required follow-up work: 

• Install TRANSMISSION .

Installation (installing new clutch): 

The DISENGAGEMENT MODULE  included in the new replacement clutch set and the new GUIDE SLEEVE must be installed.

Check the BALL HUB  and replace it if necessary.

Ball hubs differ in length, diameter and visually by the flat portion (1)! See graphic.

It must be ensured that the same ball hub is installed again! 

Non-compliance may lead to damage to the clutch and transmission!

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Center clutch disc (1) with special tool 2 358 471.

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Push clutch onto dowel pins (1) located in flywheel and tighten down the screws.

Part:  Replace screws.

Tightening torque 21 21 1AZ .

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Carefully unscrew stop (1) clockwise or counterclockwise using a size 14 (2) Allen wrench.

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2 358 471 Withdraw special tool from clutch disc with aid of accompanying screw (1).

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Necessary reworking: 

• Install TRANSMISSION .