Remove/install clutch actuator

AR25.20-G-3000OHC

Remove/install clutch actuator

09.08.2018

Model

800.1 with transmission 715.386/536

with code GG3Y (VIAB start-off and braking system)

1

Electrical wiring harness

2

Bracket

3

Bolts

4

Compressed-air line

5

Clutch actuator

6

Screw

B503

Clutch travel sensor

Notes on compressed air connection systems

AH00.18-N-0001-01A



Remove

1

Detach electrical connection from clutch position sensor (B503)

2

Expose electrical wiring harness (1) on bracket (2)

3

Remove screws (3) and remove holder (2) at transmission

4

Detach air line (4) from clutch actuator (5)

5

Remove screws (6) and remove clutch actuator (5)

6

Remove tappet of clutch actuator (5)

7

Check ball head and guide of tappet for wear or damage

If the ball head or the guide of the tappet is worn or damaged.



Replace tappet of clutch actuator (5).



Install

8

Adjust tappet of clutch actuator (5)

Only if the clutch or tappet of the clutch actuator (5) was replaced.

AR25.20-G-3000-01OHC

 Jam nut to plunger of clutch actuator

*BA25.50-N-1025-01B

 Adjusting device

*930589002300

 Knurled screw

*930589002305

9

Lightly grease ball head and guide of tappet with lubricant

Long-life grease

*BR00.45-Z-1001-06A

10

Install tappet of clutch actuator (5)

11

Install clutch actuator (5)

 Bolt, clutch actuator to housing for fluid coupling

*BA25.50-N-1024-01B

12

Mount air line (4) to clutch actuator (5)

13

Attach holder (2) to transmission

14

Fasten electrical wiring harness (1) to bracket (2)

15

Connect electrical connection to clutch position sensor (B503)

16

Connect diagnostic system and perform quick test

 See information from body manufacturer.

17

Check software release in transmission control unit (TCM) and update if necessary

Only if the clutch or tappet of the clutch actuator (5) was replaced.

 See information from body manufacturer.

18

Select teach-in process "Clutch teach-in"

 The process is completely menu-assisted under:
TCM - transmission control (A5) 
Adaptations 
Teach-in processes 
Teach-in of clutch

19

Detach diagnostic system

 Fluid coupling

Number

Designation

Model 800.1
with code GG3Y (VIAB start-off and braking system)

BA25.50-N-1024-01B

Bolt, clutch actuator to housing for fluid coupling

Nm

55

 Fluid coupling

Number

Designation

Model 800.1
with code GG3Y (VIAB start-off and braking system)

BA25.50-N-1025-01B

Jam nut to plunger of clutch actuator

Nm

40

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11