Remove/install clutch

AR25.10-T-0050CB

Remove/install clutch

9.3.10



Remove

1

Remove clutch booster (17)

 The transmission (15) is removed when the clutch booster (17) is removed. Do not detach the lines on the clutch booster (17).

AR25.20-T-0300CA

2

Remove transmission (15)

 As soon as the transmission (15) is separated from the engine housing, the clutch throwout lever (6) releases from the groove in the clutch release bearing (1). The clutch release bearing (1) remains on the pressure plate (3).

AR26.10-T-0020CB

3

Remove release bearing (1)

AR25.10-T-0050-03BA

4

Install the assembly device on the pressure plate (3)

Assembly device base unit for removing/installing clutch pressure plates and flywheels,

Firma BlitzRotary GmbH D-78199 Bräunlingen

EVO-Bus additional kit of assembly device for removing/installing clutch pressure plates and flywheels,

Firma BlitzRotary GmbH D-78199 Bräunlingen

Pressure diecast housing for adaptation of assembly device for removing/installing clutch pressure plates and flywheels,

Firma BlitzRotary GmbH D-78199 Bräunlingen

5

Remove pressure plate (3) with clutch plate (4)

 To prevent subjecting pressure plate (3) to one-sided loads, unscrew bolts (5) by turning each one by just a small increment while also working in a cross-pattern. Observe installation position of clutch plate (4).



Check

6

Check the friction surface of the pressure plate (3)

 In the event of scorch marks, score marks or cracks in the friction surface the pressure plate (3) must be replaced subject to separate repair order.

7

Check friction surfaces of the clutch plate (4)

 In the event of scorch marks, score marks or cracks in the friction surface the clutch plate (4) must be replaced subject to separate repair order.

8.1

Check friction surface on flywheel

 Except in the case of the two-mass flywheel.
If there are scorch marks, score marks or cracks on the friction surface, the flywheel must be post-worked or replaced.



Remove/install flywheel

AR03.30-T-8002BB

8.2

Check two-mass flywheel

 The two-mass flywheel must not be repaired or post-worked. In the event of damage or wear, replace the two-mass flywheel subject to separate repair order.



AR03.30-T-8002-01BB

Remove/install flywheel

AR03.30-T-8002BB

9

Check and slightly grease guide bearing in flywheel

 Replace worn guide bearing subject to separate repair order:

*BR00.45-Z-1062-06A

10

Check release bearing (1) for ease of movement and wear.

 Replace worn clutch bearing (1) subject to separate repair order.

11

Check clutch throwout lever (6) for ease of movement and wear

 In the event of sluggishness and detectable wear, remove and disassemble the clutch throwout lever (6), free off and replace if necessary: 

Remove and install clutch throwout lever

AR25.20-T-0200B

12

Grease the profile grooves in the clutch plate (4) lightly and check that the clutch plate (4) can be moved on the hub profile of the transmission shaft (7)

 It must be possible to slide the clutch plate (4) over the hub profile of the transmission shaft (7) easily and without excessive play.
Remove excess grease.

*BR00.45-Z-1062-06A



Install

13

Center the clutch plate (4) on the flywheel using a suitable alignment punch

 Observe installation position of clutch plate (4). Only remove the alignment punch after fully tightening the pressure plate (3).

14

Install pressure plate (3) on the flywheel

 Installation: Pay attention to the correct bolt length in order to prevent damage to the flywheel.

 Tighten the bolts (5) in small stages in a crosswise pattern. It must still be possible to move alignment punch axially after tightening bolts. Check the correct seat of the circlip (2) and lock it in position.



*BA25.10-N-1002-01F



*000589642100

15

Remove the alignment punch

16

Detach assembly device from the pressure plate (3)

Assembly device base unit for removing/installing clutch pressure plates and flywheels,

Firma BlitzRotary GmbH D-78199 Bräunlingen

EVO-Bus additional kit of assembly device for removing/installing clutch pressure plates and flywheels,

Firma BlitzRotary GmbH D-78199 Bräunlingen

Pressure diecast housing for adaptation of assembly device for removing/installing clutch pressure plates and flywheels,

Firma BlitzRotary GmbH D-78199 Bräunlingen

17

Install clutch bearing (1)

 Grease the transmission shaft (7) lightly. Remove excess grease.

AR25.10-T-0050-03BA

*BR00.45-Z-1062-06A

18

Install transmission (15)

 The clutch bearing (1) can be engaged in the circlip (2) by hand through the opening in the clutch housing (14) with the aid of the clutch throwout lever (6) when the clutch booster (17) is removed.

AR26.10-T-0020CB

Number

Designation

Engine 457

BA25.10-N-1002-01F

Bolt, pressure plate to flywheel

Nm

55

Number

Designation

Order number

BR00.45-Z-1062-06A

Lubricating grease, Olista Longtime, DB supply specification 6804.60

A 001 989 36 51 10