5 SPD. M/T 012/01W FWD

Clutch release mechanism, servicing





1 - Slave cylinder
^ Do not operate clutch pedal after slave cylinder has been removed.
^ Separating from hose and line assembly
^ Installing
^ When installing, press in slave cylinder far enough so that securing bolt can be installed easily.
^ Tighten bleed valve to 4.5 Nm
^ Bleeding clutch system

2 - Hex socket-head bolt, 23 Nm
^ Slave cylinder to transmission
^ Self-locking
^ Always replace





3 - Bracket
^ For hose and line assembly
^ Secured to transmission with slave cylinder
^ Installing

4 - Push rod
^ Lubricate end of push rod with copper grease, e.g. Z 381 351 TE

5 - Dished washer
^ Smaller diameter (convex side) to guide sleeve

6 - Input shaft oil seal
^ Available with guide sleeve -item 11 - as replacement part





7 - Torx socket head bolt
^ Self-locking
^ Always replace
^ Black; only for aluminum transmission
^ Allocation
go to Parts list
^ On aluminum transmission tighten to 35 Nm

8 - Release bearing
^ With or without plastic ring depending on design
^ Adhering detached plastic ring
^ Do not wash out bearing, only wipe
^ Replace noisy bearings
^ Allow retaining lugs on release bearing to engage in release lever





9 - Clutch release lever
^ Coat contact surface of clutch slave cylinder push rod with copper grease, e.g. Z 381 351 TE before installing

10 - Retaining spring
^ Secure to clutch release lever

11 - Guide sleeve
^ Available with oil seal -item 6 - as replacement part
^ Installation position: Oil drain hole points downward
^ Cover input shaft splines with a shrink-fit hose to protect oil seal -item 6 - before removing and installing





12 - O-ring
^ Always replace

13 - Intermediate piece
14 - Ball stud
^ Lubricate with MoS2-grease
^ On aluminum transmissions tighten to 25 Nm





Fig. 1 Separating slave cylinder from hose and line assembly
Removing
- Use a screwdriver to remove hose and line assembly, pry out clip -A- up to stop. Then pulled out the hose and line assembly.

Installing
- Press in clip -A- up to stop
- Insert hose and line assembly into slave cylinder until it is heard to engage.
- Test by pulling on hose and line assembly.





Fig. 2 Before installing, coat clutch slave cylinder with grease
- Lightly lubricate contact surface for push rod at clutch release lever with copper grease, e.g. Z 381 351 TE.
- Lubricate area -a- on boot with lithium grease G 052 150 A2 before fitting slave cylinder into transmission housing.





Fig. 3 Installing clutch slave cylinder
- Fasten bracket for hose line assembly -3- onto slave cylinder -4- and bolt together slave cylinder to transmission.
- Insert the clutch slave cylinder into the mounting hole of the transmission housing, keep it in line with the direction of operation of the push rod.

Note:
^ There is a danger that the push rod will be guided past the clutch release lever if the clutch slave cylinder -4- is inserted off-fine.
^ Press in the clutch slave cylinder far enough so that the securing bolt can be fitted easily. Replace securing bolt -2-.





Fig. 4 Servicing release bearing with plastic ring
On release bearings with plastic ring it is possible that the plastic ring detaches from the release bearing during removal of transmission or release bearing; this is not a reason for replacing release bearing.
- Adhere plastic ring back onto bearing ring with adhesive AMV 195 KD1 01 before installing transmission.
Three right-angled lugs -arrows- on plastic ring engage in the recesses of bearing ring.

Note: The release bearing must be replaced if the plastic ring lies deeper than 0.5 mm on the contact surface.