Remove/install clutch

AR25.10-B-0050L

Remove/install clutch

04.08.2020

Model

979 with engine 904.943, 924.9

Model

979 with engine 924.9

Represented in vehicle 979.046 engine 904.943

1

Clutch disk

2

Clutch plate

3

Washer

4

Bolt

5.1

Clutch bearing

6

Hydraulic clutch driving unit

7

Connection pipe

8

Centering mandrel

Represented in vehicle 979.026 engine 924.991

1

Clutch disk

2

Clutch plate

3

Washer

4

Bolt

5.2

Clutch bearing

8

Centering mandrel

9

Clutch fork



Remove

 Caution

Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid

Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

AS42.50-Z-0001-01A

1

Detach the hydraulic line of the connection pipe (7) and fully bleed the system

2

Transmission removal

Only vehicles 979 with gearbox 710.27

AR26.10-B-0020H

Only for vehicles 979 with transmission 712.45 and 712.36

AR26.10-B-0020K

3

Remove the bolts (4) and remove the clutch plate (2) along with the clutch disc (1)

 Unscrew the bolts (4) alternately, crosswise. Unfasten the gradually, in order to avoid excessive unilateral load on the plate. Pay attention to the clutch disc position.



Check

4

Check the clutch plate (2) and the clutch disc (1) for wear

 In case of cracks, signs of overheating or wear of the friction surface:
Replace clutch disc or plate.

.Axial displacement of the clutch disc

*BE25.10-B-1001-01D

.Minimum allowable thickness of the clutch disc

*BE25.10-B-1002-01D

5

Check the engine flywheel for wear and damage

 In case of cracks or damage of the friction surface, repair the engine flywheel:

Outside flywheel diameter

*BE03.30-B-1001-03E

Ring gear housing diameter

*BE03.30-B-1002-03E

Flywheel diameter on the crankshaft flange

*BE03.30-B-1003-03E

Clutch housing diameter

*BE03.30-B-1004-03E

Maximum permissible flywheel runout (measured in the gear rack seat surface)

*BE03.30-B-1005-03E

Flywheel working face finishing roughness, Rz

*BE03.30-B-1006-03E

Total flywheel thickness

*BE03.30-B-1007-03E

Minimum allowable distance between the friction surface and the contact surface with the crankshaft

*BE03.30-B-1008-03E

Maximum allowable side deviation of the flywheel friction surface

*BE03.30-B-1009-03E

Maximum dynamic unbalance of the flywheel with rack

*BE03.30-B-1010-03E

Maximum length for the reutilization of the flywheel bolts

*BE03.30-B-1011-03E

Inside rack diameter

*BE03.30-B-1012-03E

Interference between the gear rack and flywheel

*BE03.30-B-1013-03E

Maximum allowable side deviation of the rack

*BE03.30-B-1014-03E

Radial eccentricity of the rack/flywheel

*BE03.30-B-1015-03E

Rack width

*BE03.30-B-1016-03E

Rack assembly temperature

*BE03.30-B-1017-03E

6

Check the engine flywheel guide bearing for wear and damage

 In case of clear wear and damage, or faulty operation, replace the engine flywheel guide bearing.

7.1

Check the clutch bearing (5.1) of the hydraulic clutch drive (6) for wear and damage

In case of wear or damage of the clutch bearing (5.1):

Remove/install central clutch operator.

AR25.20-B-0180A

7.2

Check the clutch bearing (5.2) of the clutch drive system for wear and damage

In case of wear or damage of the clutch bearing (5.2), replace the clutch bearing (5.2)

8

Check the clutch actuation system fluid, for contamination

 In the case of fluid contamination, wash the actuation system and replace the fluid.

 Check the conditions of the master cylinder. If necessary, remove it and repair it.

9

Check the conditions of the clutch actuation pneumatic system

 Vehicles equipped with hydro-servo-pneumatic cylinder. In the case of contamination with water in the pneumatic part, drain the reservoirs and check the conditions of the draining valve. In the case of contamination of the pneumatic part, by engine oil, check the air compressor conditions.

10

Lightly grease the clutch disc hub (1) and check the ease of displacement on the main shaft

 The disc must move easily on the drive shaft, without presenting excessive play

 Dispose of the excess grease (risk of contamination of the lining of the clutch disc.

Grease, DB supply specification 6811.00.20 - Class 266.2

*BR00.45-Z-1106-06A



Install

11

Install the clutch disc (1) with the clutch plate (2), using the centering mandrel (8)

 Assure correct mounting position for clutch disk. Remove the centering mandrel only after the tightening of the plate fastening bolts.

 Tighten the bolts (4) alternately and gradually. While tightening, continuously check if the mandrel can be easily dislodged. If the clutch disc (1) is installed eccentrically, there will be problems while installing the gearbox.

 Clutch pressure plate fastening to engine flywheel

*BA25.10-B-1001-01M

 Centering drift

*677589006100

12

Transmission installation

Only vehicles 979 with gearbox 710.27

AR26.10-B-0020H

Only for vehicles 979 with transmission 712.45 and 712.36

AR26.10-B-0020K

13

Connect the hydraulic line to the connection pipe (7)

14

Supply and bleed the clutch actuation system

Bleed clutch operating system
.

AR25.20-B-0070E

Engine flywheel

Number

Designation

Engine 904.9 with Ø 443 flywheel and Ø 362 clutch

Motor 902.9; 904.9, 906.9, 924.9 with Ø 443 flywheel and Ø 395 clutch

BE03.30-B-1001-03E

Outside flywheel diameter

mm

443

443

Engine flywheel

Number

Designation

Motor 904.9; 924.9 with Ø 403 flywheel and Ø 362 clutch

Motor 902.9, 906.9, 924.9 with Ø 443 flywheel and automatic gearbox

BE03.30-B-1001-03E

Outside flywheel diameter

mm

403

443

Engine flywheel

Number

Designation

Motor 904.9 with Ø 403 flywheel with automatic gearbox

Engine 902.9, 904.9, 906.9, 924.9, with Ø 443 flywheel and Spicer clutch

BE03.30-B-1001-03E

Outside flywheel diameter

mm

403

443

Engine flywheel

Number

Designation

Engine 904.9 with Ø 443 flywheel and Ø 362 clutch

Motor 902.9; 904.9, 906.9, 924.9 with Ø 443 flywheel and Ø 395 clutch

BE03.30-B-1002-03E

Ring gear housing diameter

mm

392,435...392,575

392,435...392,575

Engine flywheel

Number

Designation

Motor 904.9; 924.9 with Ø 403 flywheel and Ø 362 clutch

Motor 902.9, 906.9, 924.9 with Ø 443 flywheel and automatic gearbox

BE03.30-B-1002-03E

Ring gear housing diameter

mm

360,435...360,575

392,435...392,575

Engine flywheel

Number

Designation

Motor 904.9 with Ø 403 flywheel with automatic gearbox

Engine 902.9, 904.9, 906.9, 924.9, with Ø 443 flywheel and Spicer clutch

BE03.30-B-1002-03E

Ring gear housing diameter

mm

360,435...360,575

392,435...392,575

Engine flywheel

Number

Designation

Engine 904.9 with Ø 443 flywheel and Ø 362 clutch

Motor 902.9; 904.9, 906.9, 924.9 with Ø 443 flywheel and Ø 395 clutch

BE03.30-B-1003-03E

Flywheel diameter on the crankshaft flange

mm

114,960...115,020

114,960...115,020

Engine flywheel

Number

Designation

Motor 904.9; 924.9 with Ø 403 flywheel and Ø 362 clutch

Motor 902.9, 906.9, 924.9 with Ø 443 flywheel and automatic gearbox

BE03.30-B-1003-03E

Flywheel diameter on the crankshaft flange

mm

114,960...115,020

114,960...115,020

Engine flywheel

Number

Designation

Motor 904.9 with Ø 403 flywheel with automatic gearbox

Engine 902.9, 904.9, 906.9, 924.9, with Ø 443 flywheel and Spicer clutch

BE03.30-B-1003-03E

Flywheel diameter on the crankshaft flange

mm

114,960...115,020

114,960...115,020

Engine flywheel

Number

Designation

Engine 904.9 with Ø 443 flywheel and Ø 362 clutch

Motor 902.9; 904.9, 906.9, 924.9 with Ø 443 flywheel and Ø 395 clutch

BE03.30-B-1004-03E

Clutch housing diameter

mm

395,000...395,140

435,000...435,155

Engine flywheel

Number

Designation

Motor 904.9; 924.9 with Ø 403 flywheel and Ø 362 clutch

Motor 902.9, 906.9, 924.9 with Ø 443 flywheel and automatic gearbox

BE03.30-B-1004-03E

Clutch housing diameter

mm

395,000...395,140

-

Engine flywheel

Number

Designation

Motor 904.9 with Ø 403 flywheel with automatic gearbox

Engine 902.9, 904.9, 906.9, 924.9, with Ø 443 flywheel and Spicer clutch

BE03.30-B-1004-03E

Clutch housing diameter

mm

-

435,000...435,097

Engine flywheel

Number

Designation

Engine 904.9 with Ø 443 flywheel and Ø 362 clutch

Motor 902.9; 904.9, 906.9, 924.9 with Ø 443 flywheel and Ø 395 clutch

BE03.30-B-1005-03E

Maximum permissible flywheel runout (measured in the gear rack seat surface)

mm

0,2

0,2

Engine flywheel

Number

Designation

Motor 904.9; 924.9 with Ø 403 flywheel and Ø 362 clutch

Motor 902.9, 906.9, 924.9 with Ø 443 flywheel and automatic gearbox

BE03.30-B-1005-03E

Maximum permissible flywheel runout (measured in the gear rack seat surface)

mm

0,2

-

Engine flywheel

Number

Designation

Motor 904.9 with Ø 403 flywheel with automatic gearbox

Engine 902.9, 904.9, 906.9, 924.9, with Ø 443 flywheel and Spicer clutch

BE03.30-B-1005-03E

Maximum permissible flywheel runout (measured in the gear rack seat surface)

mm

-

-

Engine flywheel

Number

Designation

Engine 904.9 with Ø 443 flywheel and Ø 362 clutch

Motor 902.9; 904.9, 906.9, 924.9 with Ø 443 flywheel and Ø 395 clutch

BE03.30-B-1006-03E

Flywheel working face finishing roughness, Rz

mm

0,016

0,016

Engine flywheel

Number

Designation

Motor 904.9; 924.9 with Ø 403 flywheel and Ø 362 clutch

Motor 902.9, 906.9, 924.9 with Ø 443 flywheel and automatic gearbox

BE03.30-B-1006-03E

Flywheel working face finishing roughness, Rz

mm

0,016

0,016

Engine flywheel

Number

Designation

Motor 904.9 with Ø 403 flywheel with automatic gearbox

Engine 902.9, 904.9, 906.9, 924.9, with Ø 443 flywheel and Spicer clutch

BE03.30-B-1006-03E

Flywheel working face finishing roughness, Rz

mm

-

0,016

Engine flywheel

Number

Designation

Engine 904.9 with Ø 443 flywheel and Ø 362 clutch

Motor 902.9; 904.9, 906.9, 924.9 with Ø 443 flywheel and Ø 395 clutch

BE03.30-B-1007-03E

Total flywheel thickness

mm

64

64

Engine flywheel

Number

Designation

Motor 904.9; 924.9 with Ø 403 flywheel and Ø 362 clutch

Motor 902.9, 906.9, 924.9 with Ø 443 flywheel and automatic gearbox

BE03.30-B-1007-03E

Total flywheel thickness

mm

64

56

Engine flywheel

Number

Designation

Motor 904.9 with Ø 403 flywheel with automatic gearbox

Engine 902.9, 904.9, 906.9, 924.9, with Ø 443 flywheel and Spicer clutch

BE03.30-B-1007-03E

Total flywheel thickness

mm

-

56

Engine flywheel

Number

Designation

Engine 904.9 with Ø 443 flywheel and Ø 362 clutch

Motor 902.9; 904.9, 906.9, 924.9 with Ø 443 flywheel and Ø 395 clutch

BE03.30-B-1008-03E

Minimum allowable distance between the friction surface and the contact surface with the crankshaft

mm

55

55

Engine flywheel

Number

Designation

Motor 904.9; 924.9 with Ø 403 flywheel and Ø 362 clutch

Motor 902.9, 906.9, 924.9 with Ø 443 flywheel and automatic gearbox

BE03.30-B-1008-03E

Minimum allowable distance between the friction surface and the contact surface with the crankshaft

mm

55

-

Engine flywheel

Number

Designation

Motor 904.9 with Ø 403 flywheel with automatic gearbox

Engine 902.9, 904.9, 906.9, 924.9, with Ø 443 flywheel and Spicer clutch

BE03.30-B-1008-03E

Minimum allowable distance between the friction surface and the contact surface with the crankshaft

mm

-

55

Engine flywheel

Number

Designation

Engine 904.9 with Ø 443 flywheel and Ø 362 clutch

Motor 902.9; 904.9, 906.9, 924.9 with Ø 443 flywheel and Ø 395 clutch

BE03.30-B-1009-03E

Maximum allowable side deviation of the flywheel friction surface

mm

0,1

0,1

Engine flywheel

Number

Designation

Motor 904.9; 924.9 with Ø 403 flywheel and Ø 362 clutch

Motor 902.9, 906.9, 924.9 with Ø 443 flywheel and automatic gearbox

BE03.30-B-1009-03E

Maximum allowable side deviation of the flywheel friction surface

mm

0,1

-

Engine flywheel

Number

Designation

Motor 904.9 with Ø 403 flywheel with automatic gearbox

Engine 902.9, 904.9, 906.9, 924.9, with Ø 443 flywheel and Spicer clutch

BE03.30-B-1009-03E

Maximum allowable side deviation of the flywheel friction surface

mm

-

-

Engine flywheel

Number

Designation

Engine 904.9 with Ø 443 flywheel and Ø 362 clutch

Motor 902.9; 904.9, 906.9, 924.9 with Ø 443 flywheel and Ø 395 clutch

BE03.30-B-1010-03E

Maximum dynamic unbalance of the flywheel with rack

mm

0,2

0,2

Engine flywheel

Number

Designation

Motor 904.9; 924.9 with Ø 403 flywheel and Ø 362 clutch

Motor 902.9, 906.9, 924.9 with Ø 443 flywheel and automatic gearbox

BE03.30-B-1010-03E

Maximum dynamic unbalance of the flywheel with rack

mm

0,2

0,2

Engine flywheel

Number

Designation

Motor 904.9 with Ø 403 flywheel with automatic gearbox

Engine 902.9, 904.9, 906.9, 924.9, with Ø 443 flywheel and Spicer clutch

BE03.30-B-1010-03E

Maximum dynamic unbalance of the flywheel with rack

mm

-

-

Engine flywheel

Number

Designation

Engine 904.9 with Ø 443 flywheel and Ø 362 clutch

Motor 902.9; 904.9, 906.9, 924.9 with Ø 443 flywheel and Ø 395 clutch

BE03.30-B-1011-03E

Maximum length for the reutilization of the flywheel bolts

mm

61

61

Engine flywheel

Number

Designation

Motor 904.9; 924.9 with Ø 403 flywheel and Ø 362 clutch

Motor 902.9, 906.9, 924.9 with Ø 443 flywheel and automatic gearbox

BE03.30-B-1011-03E

Maximum length for the reutilization of the flywheel bolts

mm

61

61

Engine flywheel

Number

Designation

Motor 904.9 with Ø 403 flywheel with automatic gearbox

Engine 902.9, 904.9, 906.9, 924.9, with Ø 443 flywheel and Spicer clutch

BE03.30-B-1011-03E

Maximum length for the reutilization of the flywheel bolts

mm

61

61

Engine flywheel

Number

Designation

Engine 904.9 with Ø 443 flywheel and Ø 362 clutch

Motor 902.9; 904.9, 906.9, 924.9 with Ø 443 flywheel and Ø 395 clutch

BE03.30-B-1012-03E

Inside rack diameter

mm

392,000...392,140

392,000...392,140

Engine flywheel

Number

Designation

Motor 904.9; 924.9 with Ø 403 flywheel and Ø 362 clutch

Motor 902.9, 906.9, 924.9 with Ø 443 flywheel and automatic gearbox

BE03.30-B-1012-03E

Inside rack diameter

mm

359,830...359,690

392,000...392,140

Engine flywheel

Number

Designation

Motor 904.9 with Ø 403 flywheel with automatic gearbox

Engine 902.9, 904.9, 906.9, 924.9, with Ø 443 flywheel and Spicer clutch

BE03.30-B-1012-03E

Inside rack diameter

mm

-

-

Engine flywheel

Number

Designation

Engine 904.9 with Ø 443 flywheel and Ø 362 clutch

Motor 902.9; 904.9, 906.9, 924.9 with Ø 443 flywheel and Ø 395 clutch

BE03.30-B-1013-03E

Interference between the gear rack and flywheel

mm

0,295...0,575

0,295...0,575

Engine flywheel

Number

Designation

Motor 904.9; 924.9 with Ø 403 flywheel and Ø 362 clutch

Motor 902.9, 906.9, 924.9 with Ø 443 flywheel and automatic gearbox

BE03.30-B-1013-03E

Interference between the gear rack and flywheel

mm

0,295...0,575

-

Engine flywheel

Number

Designation

Motor 904.9 with Ø 403 flywheel with automatic gearbox

Engine 902.9, 904.9, 906.9, 924.9, with Ø 443 flywheel and Spicer clutch

BE03.30-B-1013-03E

Interference between the gear rack and flywheel

mm

-

-

Engine flywheel

Number

Designation

Engine 904.9 with Ø 443 flywheel and Ø 362 clutch

Motor 902.9; 904.9, 906.9, 924.9 with Ø 443 flywheel and Ø 395 clutch

BE03.30-B-1014-03E

Maximum allowable side deviation of the rack

mm

0,05

0,05

Engine flywheel

Number

Designation

Motor 904.9; 924.9 with Ø 403 flywheel and Ø 362 clutch

Motor 902.9, 906.9, 924.9 with Ø 443 flywheel and automatic gearbox

BE03.30-B-1014-03E

Maximum allowable side deviation of the rack

mm

0,5

0,5

Engine flywheel

Number

Designation

Motor 904.9 with Ø 403 flywheel with automatic gearbox

Engine 902.9, 904.9, 906.9, 924.9, with Ø 443 flywheel and Spicer clutch

BE03.30-B-1014-03E

Maximum allowable side deviation of the rack

mm

0,05

-

Engine flywheel

Number

Designation

Engine 904.9 with Ø 443 flywheel and Ø 362 clutch

Motor 902.9; 904.9, 906.9, 924.9 with Ø 443 flywheel and Ø 395 clutch

BE03.30-B-1015-03E

Radial eccentricity of the rack/flywheel

mm

0,5

0,5

Engine flywheel

Number

Designation

Motor 904.9; 924.9 with Ø 403 flywheel and Ø 362 clutch

Motor 902.9, 906.9, 924.9 with Ø 443 flywheel and automatic gearbox

BE03.30-B-1015-03E

Radial eccentricity of the rack/flywheel

mm

0,5

-

Engine flywheel

Number

Designation

Motor 904.9 with Ø 403 flywheel with automatic gearbox

Engine 902.9, 904.9, 906.9, 924.9, with Ø 443 flywheel and Spicer clutch

BE03.30-B-1015-03E

Radial eccentricity of the rack/flywheel

mm

-

-

Engine flywheel

Number

Designation

Engine 904.9 with Ø 443 flywheel and Ø 362 clutch

Motor 902.9; 904.9, 906.9, 924.9 with Ø 443 flywheel and Ø 395 clutch

BE03.30-B-1016-03E

Rack width

mm

15,6...16,0

15,6...16,0

Engine flywheel

Number

Designation

Motor 904.9; 924.9 with Ø 403 flywheel and Ø 362 clutch

Motor 902.9, 906.9, 924.9 with Ø 443 flywheel and automatic gearbox

BE03.30-B-1016-03E

Rack width

mm

15,6...16,0

15,6...16

Engine flywheel

Number

Designation

Motor 904.9 with Ø 403 flywheel with automatic gearbox

Engine 902.9, 904.9, 906.9, 924.9, with Ø 443 flywheel and Spicer clutch

BE03.30-B-1016-03E

Rack width

mm

-

-

Engine flywheel

Number

Designation

Engine 904.9 with Ø 443 flywheel and Ø 362 clutch

Motor 902.9; 904.9, 906.9, 924.9 with Ø 443 flywheel and Ø 395 clutch

BE03.30-B-1017-03E

Rack assembly temperature

°C

250...280

250...280

Engine flywheel

Number

Designation

Motor 904.9; 924.9 with Ø 403 flywheel and Ø 362 clutch

Motor 902.9, 906.9, 924.9 with Ø 443 flywheel and automatic gearbox

BE03.30-B-1017-03E

Rack assembly temperature

°C

250...280

250...280

Engine flywheel

Number

Designation

Motor 904.9 with Ø 403 flywheel with automatic gearbox

Engine 902.9, 904.9, 906.9, 924.9, with Ø 443 flywheel and Spicer clutch

BE03.30-B-1017-03E

Rack assembly temperature

°C

-

-

Clutch

Number

Designation

Engine 904.9, 906.9, 924.9, 926.9
with clutch MF 362

Engine 904.9, 906.9, 924.9, 926.9
with clutch MFZ 395

BE25.10-B-1001-01D

Axial displacement of the clutch disc

mm

0,50

0,50

Clutch

Number

Designation

Engine 904.9, 906.9, 924.9, 926.9
with clutch MF 362

Engine 904.9, 906.9, 924.9, 926.9
with clutch MFZ 395

BE25.10-B-1002-01D

Minimum allowable thickness of the clutch disc

mm

9,7...10,3

9,7...10,3

 Clutch

Number

Designation

Engine 904.9; 924.9 with MF 362 clutch

Engine 904.9, 924.9 with MF 395 clutch

BA25.10-B-1001-01M

Clutch pressure plate fastening to engine flywheel

Nm

30

58

Repair materials

Number

Designation

Order number

BR00.45-Z-1106-06A

Grease, DB supply specification 6811.00.20 - Class 266.2

Use corresponding commercially available repair materials.