5 SPD. M/T 01A AWD

Clutch release mechanism components (on transmission), servicing





1 - Transmission
2 - Ball pivot, 25 Nm
^ Lubricate with MoS2 grease
3 - Intermediate piece
4 - Dished washer
^ Small diameter (convex side) facing guide sleeve
5 - O-ring
^ Always replace
6 - Oil seal for input shaft
^ Available together with guide sleeve -item 7 - as one part
7 - Guide sleeve
^ Available together with oil seal -item 6 - as one part
^ Installation position: Oil drain hole facing downward
^ To protect oil seal -item 6 - place shrink down tube over input shaft splines
8 - Retaining spring
^ Attach to clutch release lever
9 - Internal TORX head bolt, 35 Nm
^ Self-locking Always replace
10 - Clutch release lever
^ Before installing lubricate locating recess for plunger of clutch slave cylinder with copper paste e.g. Z 381 351 TE
11 - Release bearing
^ With or without plastic ring, depending on design
^ Glue on detached plastic ring
^ Never wash out bearing; only wipe Replace noisy bearings Lock retaining tabs on release bearing in release lever
12 - Slave cylinder
^ Do not press clutch pedal after removal
^ Separating from hose/pipe assembly
^ Installing
^ Pre-load slave cylinder so that securing bolt can be installed easily
^ Tighten bleeder valve to 4.5 Nm
^ Bleed clutch system
13 - Hex socket-head bolt, 23 Nm
^ Slave cylinder to transmission
^ Self-locking
^ Always replace
14 - Bracket
^ For hose/pipe assembly
^ Attached to transmission together with slave cylinder Installing

15 - Plunger Lubricate end of plunger with copper paste, e.g. Z 381 351 TE

Fig. 1 Separating slave cylinder from hose/pipe assembly:

Removing
To remove hose/pipe assembly use a screwdriver to pry out clip -A- as far as it will go. Only then can the hose/pipe assembly be pulled out.

Installing
- Push in clip -A- as far as it will go.
- Insert hose/pipe assembly in slave cylinder until it clicks into position.
- Check proper installation by pulling hose/pipe assembly.

Fig. 2 Lubricating clutch slave cylinder with grease before installing:

-Apply a thin layer of copper paste, e.g. Z 381 351 TE, to contact surface for plunger on clutch release lever
- Before installing slave cylinder in transmission housing lubricate area a- of boot with lithium base grease G 052 150 A2.

Fig. 3 Installing clutch slave cylinder:

- Lock bracket for hose/pipe assembly -3- on slave cylinder -4- and bolt onto transmission together with slave cylinder.
- Insert clutch slave cylinder into hole of transmission housing without major lateral deviation from direction of motion of plunger.

Note:
^ If clutch slave cylinder -4- is not kept straight during insertion there is a risk that the plunger might move past the clutch release lever.
^ Pre-load clutch slave cylinder so that securing bolt can be installed easily.
^ Replace securing bolt -2,

Fig. 4 Servicing release bearing with plastic ring:

In the case of release bearings with plastic ring the latter may become detached from the release bearing during the removal of the transmission or the release bearing. This does not mean that the release bearing has to be replaced.
- Before installing transmission glue loose plastic ring onto bearing ring with adhesive AMV 195 KD1 01.
Three square lugs -arrows- of plastic ring locate in recesses of bearing ring.

Note: If running face of plastic ring is worn by more than 0.5 mm, you must replace the release bearing.