Remove/install clutch housing

AR25.10-G-0040B

Remove/install clutch housing

28.05.2018

Model

405.100/101/102/103/120/121/122/123/200/201/220/221

Shown on engine 904

1

Connector

2

Hydraulic line

3

Drive shaft

4

Coupling flange

5

Plug connector

6

Bracket

7

Clutch housing

B2

GS (EPS) clutch travel sensor

 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

 

Remove/install

1

Extract brake fluid from expansion reservoir of clutch operating system

Topical note

Brake fluid notes

AH42.50-P-0001-01A

2

Tilt cab

AR60.80-G-0005B

3

Unclip retainer at connector (1) and disconnect hydraulic line (2)

 Collect escaping brake fluid.

 Installation: Replace seal.

4

Detach drive shaft (3) from connector flange (4)

 Fix drive shaft (3) in place above.

 Bolt, drive shaft to coupling flange

*BA25.10-N-1001-01J

5

Detach heat shield from engine brake valve fitting

Engine 902, 906

6

Remove flexible exhaust pipe with intermediate pipe

Engine 902, 906

 Installation: Clean the sealing surface and check the clamps for wear; replace the clamps if necessary.

 Clamp, flexible exhaust pipe to valve fitting

*BA49.10-N-1001-01G

 Clamp, flexible exhaust pipe to intermediate pipe

*BA49.10-N-1003-01G

7

Remove exhaust pipe between exhaust pot and exhaust tailpipe

Engine 902, 906 with code C87 (Upward exhaust)

8

Detach upper panel of soundproofing from frame

Engine 902, 906

9

Remove compressed air line between compressor and compressed air drier

Engine 902, 906

10

Disconnect connector plug (5) from GC clutch travel sensor (EPS) (B2)

11.1

Detach bracket (6) from clutch housing (7)

Engine 900, 904

 Place wiring hardness to side.

 Bolt, clutch housing to timing case

*BA25.10-N-1002-01J

11.2

Detach bracket (6) from timing case

Engine 902, 906

 Place wiring hardness to side.

12

Remove bolts of left and right engine mount from clutch housing (7)

 Screw/bolt connecting rear engine mount to clutch housingBolt, rear engine mount to clutch housing

*BA22.10-N-1001-01M

13

Raise engine slightly

 Secure the engine at the timing case using the jack stand.

 Commercially available devices/tools
Load regulator

14

Loosen bolt at solenoid valve bracket

 Push the solenoid valve bracket forward.

15

Remove bolts of clutch housing (7)

 Bolt, clutch housing to timing case

*BA25.10-N-1002-01J

16

Remove clutch housing (7)

 Installation: Clean the contact surfaces on the clutch housing (7) and timing case and check that they are flat; machine the contact surfaces if necessary.
Coat the contact surface on the clutch housing (7) with surface sealant.

 Installation: Up to vehicle identification end number 208109 (nickel-plated clutch drive plate and drive shaft without hard chrome plating), clean the drive shaft and lightly spray the profile grooves of the clutch drive plate and the hub profile of the drive shaft with heat-resistant lubricant.
Do not allow any heat-resistant lubricant to come into contact with the clutch lining or central clutch release bearing. There is a risk of oil fouling on the clutch lining.

 Installation: As of vehicle identification end number 208110 (nickel-plated clutch drive plate and hard-chrome-plated drive shaft), heat-resistant lubricant does not need to be sprayed on.
Only clean the drive shaft.

Loctite 5203 surface sealant

*BR00.45-Z-1129-02A

Heat-resistant lubricant

*BR00.45-Z-1074-06A

17

Install in the reverse order

18

Bleed clutch operating system

Except CODE G48 (Electronic automated gearshift (EAS))

AR25.20-G-0070B

With CODE G48 (Electronic automated gearshift (EAS))

AR25.20-G-0070BB

19

Initialize control unit for gear control (GS/EPS)

AR54.21-G-0007B

 Engine mounts, engine supports

Number

Designation

ENGINE 900.915/916, 902.923/924/935 except CODE G31

Engine 904.927/928 ## to 204901, 906.935/936/955/967 ## to 204901 except code G31

BA22.10-N-1001-01M

Bolt, rear engine mount to clutch housing

Nm

80

172

 Engine mounts, engine supports

Number

Designation

Engine 904.927/928 ## as from 204902, 906.935/936/955/967 ## as from 204902 except code G31

BA22.10-N-1001-01M

Bolt, rear engine mount to clutch housing

Nm

80

 Clutch

Number

Designation

Engine 900.91/92, 902.92/93, 904.92/95, 906.935/95, 924.91/92/93, 926.96

BA25.10-N-1001-01J

Bolt, drive shaft to coupling flange

Nm

57

 Clutch

Number

Designation

Engine 900.91/92, 902.92/93, 904.92/95, 906.935/95, 924.91/92/93, 926.96

BA25.10-N-1002-01J

Bolt, clutch housing to timing case

Nm

32

 Exhaust system

Number

Designation

Engine 900.915/916, 902.923/924

Engine 902.935, 904.927/928, 906.935/955

BA49.10-N-1001-01G

Clamp, flexible exhaust pipe to valve fitting

M8

Nm

20

20

 Exhaust system

Number

Designation

Engine 900.915/916, 902.923/924

Engine 902.935, 904.927/928, 906.935/955

BA49.10-N-1003-01G

Clamp, flexible exhaust pipe to intermediate pipe

Nm

58

–

Repair materials

Number

Designation

Order number

BR00.45-Z-1074-06A

Heat-resistant lubricant

A 000 989 91 51

BR00.45-Z-1129-02A

Loctite 5203 surface sealant

Henkel AG & Co. KGaA
http://www.loctite.de