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Gearbox mechanics,operation, construction,diff. > < Exploded view of components
Removing and installing self-adjusting clutch
   
Removing and installing self-adjusting clutch
Special tools and workshop equipment required
t  Counterhold tool -3067-
t  Centring mandrel -3190 A-
t  Centring mandrel -T10097- for clutch plate with larger hub diameter
t  Grease for clutch plate splines -G 000 100-

Removing
–  Remove gearbox → Chapter.
–  Apply counter-hold tool -3067- in order to loosen bolts.
To prevent the pressure plate from becoming distorted during removal (causes clutch grab when driving off), always adhere to the following procedure when unbolting the pressure plate:
–  Working clockwise, loosen all six bolts consecutively in steps of 90° (1/4 turn) until the pressure plate is released.
–  Take off pressure plate and clutch plate.
Installing
Installation is carried out in reverse sequence; note the following:
  Note
t  Renew clutch plate and pressure plate if riveted joints are damaged or loose.
t  If required, always renew clutch plate and pressure plate together.
t  Select the correct clutch plate and pressure plate according to engine code: → Parts catalogue.
t  If the clutch has burnt out, thoroughly clean the bell housing, flywheel and parts of the engine facing the gearbox in order to prevent odours.
t  Clean input shaft splines and (in the case of a used clutch plate) the hub splines. Remove corrosion and apply only a very thin coating of grease for clutch plate splines -G 000 100- to the splines. Then move clutch plate backwards and forwards on input shaft until hub moves freely on shaft. It is important to remove excess grease.
t  Pressure plates have an anti-corrosion coating and are greased. Only the contact surface may be cleaned, otherwise the service life of the clutch will be considerably reduced.
t  Pressure plate contact surface and clutch plate lining must make full contact with flywheel. Only then insert bolts.
–  Note correct installation position of clutch plate:
l  The marking “Getriebeseite” (gearbox side) faces towards the gearbox
   
–  Reverse position of counter-hold tool -3067- when installing.
  Note
Use centring mandrel -3190 A- to centralise clutch plate or centring mandrel -T10097- to centralise clutch plate with larger hub diameter.
To prevent the pressure plate from becoming distorted during installation (causes clutch grab when driving off), always adhere to the following procedure when installing the pressure plate:
–  Fit pressure plate onto dowel pins.
–  Screw in all 6 bolts evenly by hand until bolt heads make contact with pressure plate.
–  Working clockwise, tighten all six bolts consecutively in steps of 90° (1/4 turn) until the housing makes contact with the flywheel.
–  Working clockwise, tighten all 6 bolts to final torque consecutively.
–  Install gearbox → Chapter „Installing gearbox“.
Tightening torque
  A30-10002
ComponentNm
Pressure plate to dual-mass flywheelM613
M720
 M822

   

Gearbox mechanics,operation, construction,diff. > < Exploded view of components