Remove/install clutch actuator

AR25.20-W-3000H

Remove/install clutch actuator

20.04.2018

Model

963, 964 with engine 460.9, 470.9, 471.9, 473.9

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

Model

963, 964 with engine 460.9, 470.9, 471.9, 473.9

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

Model

963, 964 with engine 470.9, 471.9, 473.9

with code G3Y (Turbo retarder clutch)

1

Electrical wiring harness

2

Bracket

3

Bolts

4

Compressed-air line

5

Clutch actuator

6

Screw

B503

Clutch travel sensor

Topical note

Notes and information for working on clutch

AH25.00-N-0001-01A

Notes on safety-relevant components

AH00.00-Z-0019-01A



Remove

1

Detach electrical connection from clutch position sensor (B503)

2

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

3

Remove screws (3) and detach holder (2) from 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-W-3000-01H

 Jam nut to plunger of clutch actuator

*BA25.20-N-1012-01O

 Adjusting device

*930589002300

 Fahrzeuge mit Code G3Y (Turbo-Retarder-Kupplung)
Knurled screw

*930589002305

9

Install tappet of clutch actuator (5)

 Apply light coating of grease to plunger ball head and guide.

Long-life grease

*BR00.45-Z-1001-06A

10

Install clutch actuator (5)

 Bolt, clutch actuator to transmission / turbo-retarder clutch

*BA25.20-N-1011-01O

11

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

12

Attach holder (2) to transmission

13

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

14

Connect electrical connection to clutch position sensor (B503)

15

Connect diagnostic system, start XENTRY and perform quick test

16

Check software release in transmission control unit (TCM) (A5); update if necessary

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

17

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

18

End Xentry and disconnect diagnostic system

 Clutch operating system

Number

Designation

Engine 460.9

Engine 470.9, 471.9, 473.9

BA25.20-N-1011-01O

Bolt, clutch actuator to transmission / turbo-retarder clutch

Nm

55

55

 Clutch operating system

Number

Designation

Engine 460.9

Engine 470.9, 471.9, 473.9

BA25.20-N-1012-01O

Jam nut to plunger of clutch actuator

Nm

40

40

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11