Remove/install clutch

AR25.10-G-0050B

Remove/install clutch

28.03.2019

Model

405.050/100/101/102/103/120/121/122/123/200/201/220/221

Modification notes

30.03.2012

"Clean clutch components" added

Operation step 12

30.03.2012

Note on installation position of clutch plate added

Operation step 13

Shown on engine 904.927

1

Clutch plate

2

Clutch pressure plate

3

Screw

4

Central clutch release bearing

5

Coupling housing

6

Centering drift



Remove

1

Remove clutch housing (5)

MODEL 405.10/12/20/22

AR25.10-G-0040B

Model 405.050

AR25.10-G-0040E

2

Remove clutch pressure plate (2) and take off together with clutch plate (1)

 Loosen the bolts (3) in small increments in a crosswise pattern to prevent subjecting the clutch pressure plate (2) to excessive one-sided loads. Pay attention to installation position of clutch plate (1).



Check

3

Check friction surfaces on clutch pressure plate (2) and clutch plate (1).

 If there are scorch marks, score marks or cracks on the friction surface, replace defective parts.

4

Check clutch plate (1) for lateral runout

AR25.10-G-0055B

5

Check friction surface on flywheel

 If the friction surface is scorched, scored or cracked, rework flywheel:



Check flywheel, rework if necessary

AR03.30-G-8022B

6

Check and slightly grease guide bearing in flywheel

 If wear is evident, replace guide bearing:



Remove/install guide bearing in flywheel

AR03.30-G-8401B

7

Lightly grease guide bearing in flywheel

Long-life grease

*BR00.45-Z-1001-06A

8

Check central clutch release bearing (4)

 If wear is evident, replace central clutch release bearing (4):



Remove/install central clutch operator

AR25.20-G-0180B

9

Clean drive shaft

10

Lubricate drive shaft

Only on vehicles up to VIN end no. 208109 with drive shaft without hard chrome plating


Do not allow any heat-resistant lubricant to come into contact with the clutch lining or central clutch release bearing (4).
There is a risk of oil fouling on the clutch lining.

 Spray the profile grooves of the clutch plate (1) and the hub profile of the drive shaft with a thin coating of heat-resistant lubricant.

Heat-resistant lubricant

*BR00.45-Z-1074-06A

11

Check ease of movement of clutch plate (1) on hub profile of input shaft.

 It should be easy to move the clutch plate (1) over the hub profile of input shaft, but on the other hand the play should not be too large.

12

Clean clutch components

Only with CERAM clutch plate

AR25.10-G-0052C

 Before installing a new CERAM clutch plate, make absolutely certain that the clutch components are free of oil and grease.



Install

13

Center clutch plate (1) at flywheel using centering drift (6).

 Pay attention to installation position of clutch plate (1):
 "Drive-Side" must point toward clutch housing
 "Force-Side" must point toward engine
 "Engine-Side" must point toward engine
Only remove the alignment mandrel (6) after completely tightening the clutch pressure plate (2).

 Alignment punch

*906589006100

14

Install clutch pressure plate (2).

 Tighten the bolts (3) in small increments in a crosswise pattern. It must still be possible to move the alignment punch (6) slightly after tightening the bolts.
If a clutch plate (1) is clamped incorrectly or is installed off-center, difficulties occur when installing the clutch housing (5) or when shifting.

 Bolt, clutch pressure plate to flywheel

*BA25.10-N-1003-01J

 Alignment punch

*906589006100

15

Install clutch housing (5)

Remove/install clutch housing
MODEL 405.10/12/20/22

AR25.10-G-0040B

Remove/install clutch housingModel 405.050

AR25.10-G-0040E

 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-1003-01J

Bolt, clutch pressure plate to flywheel

M8

Nm

30

M10

Nm

58

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11

BR00.45-Z-1074-06A

Heat-resistant lubricant

A 000 989 91 51