Remove and install clutch throwout lever

AR25.20-W-0200H

Remove and install clutch throwout lever

20.04.2018

Model

963, 964

with code G3Y (Turbo retarder clutch)

Model

963, 964

with code N4W (Live PTO, partly clutch-dependent, MB 1.2)

Model

963, 964

with code N4X (Live PTO, partly clutch-dependent, MB, 1.65)

Model

964

with code G5H (Gearshift, manual)

1

Release lever

2

Tappet

3

Bearing sleeve

4

Retaining ring

5

Washer

6

Bearing sleeve

7

Bearing shaft

8

Guide rollers

Notes on safety-relevant components

AH00.00-Z-0019-01A



Remove

1

Remove engine, transmission or the fluid coupling with the transmission

 Select procedure according to design and accessibility.

2

Remove release lever (1)

3

Remove tappet (2) from release lever (1)



Check

4

Check bearing bushing (3) of tappet (2) for wear and damage

If wear or damage present



Install new bearing bushing (3).

5

Check bearing bushings (6), bearing shaft (7) and guide rollers (8) for wear and damage

If wear or damage present



Replace release lever (1) or disassemble release lever (1) and replace worn parts.

6

Apply a thin coating of grease to bearing point (arrow) of bearing shaft (7) and install bearing shaft (7)

Only if the release lever (1) was disassembled.

Olista Longtime lubricating grease, DB supply specification 6804.60, 100 g

*BR00.45-Z-1062-06A



Install

7

Install tappet (2) in release lever (1)

8

Apply light coating of grease to bearing points (arrows) on guide rollers (8)

Olista Longtime lubricating grease, DB supply specification 6804.60, 100 g

*BR00.45-Z-1062-06A

9

Install release lever (1)

 Vehicles with code G3Y (Turbo retarder clutch)Bolt, release lever to turbo-retarder clutch

*BA25.20-N-1010-01O

 Vehicles without code G3Y (Turbo retarder clutch)Bolt, release lever to transmission

*BA25.20-N-1005-01O

10

Install engine, transmission or the fluid coupling with the transmission

11

Connect diagnostic system, start XENTRY and perform quick test

12.1

Perform teach-in process for clutch in CPC (drive control) control unit

For vehicles with code G5H (shift mechanism, manual)

 The process is completely menu-assisted under:
CPC - drive control (A3)
Adaptations 
Teach-in processes 
Teach-in of clutch

12.2

Perform teach-in process for clutch in TCM (transmission control) control unit

On vehicles with code G3Y (Turbo retarder clutch), code N4W (Live power take-off, clutch part dependent, MB, 1.2) or code N4X (Live power take-off, clutch part dependent, MB, 1.65)

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

13

End Xentry and disconnect diagnostic system

 Clutch operating system

Number

Designation

Engine 460.9

Engine 470.9, 471.9, 473.9

BA25.20-N-1005-01O

Bolt, release lever to transmission

M10

Nm

-

-

M12

Nm

95

95

 Clutch operating system

Number

Designation

Engine 936.9

BA25.20-N-1005-01O

Bolt, release lever to transmission

M10

Nm

60

M12

Nm

95

 Clutch operating system

Number

Designation

Engine 470.9, 471.9, 473.9

BA25.20-N-1010-01O

Bolt, release lever to turbo-retarder clutch

Nm

95

Repair materials

Number

Designation

Order number

BR00.45-Z-1062-06A

Olista Longtime lubricating grease, DB supply specification 6804.60, 100 g

A 001 989 36 51 10