6 SPD. M/T 01E
Clutch release mechanism, servicing
1 - Transmission
2 - Intermediate piece
^ Replace, if damaged
3 - Shaft seal
^ For input shaft
^ Removing
^ Installing
^ Standard insertion depth: 3.5 mm, insertion depth for repairs: 4.5 mm
4 - Locating sleeve
5 - Bolt - 15 Nm
^ 3 pieces
6 - Clutch release lever
^ Removing
^ Must engage in lugs in intermediate piece when installed
^ Before installing, coat contact surface of clutch slave cylinder push rod with copper grease, e.g. Z 381 351 TE.
7 - Leaf spring
8 - Release and tighten bolt - 25 Nm
^ Self-locking
^ Always replace
9 - Release bearing
^ With or without plastic ring, depending on version
^ Cement detached plastic ring
^ Do not wash out, wipe clean only
^ Replace noisy bearings
^ Engage retaining latches at the release bearing in contact release lever
10 - Clutch slave cylinder
^ Do not operate clutch pedal after slave cylinder has been removed.
^ Follow correct work sequence when bleeding
^ Tighten bleed valve to 4.5 Nm
^ Detach from hose/pipe assembly
^ Removing
^ Installing
^ When installing, push on until the securing bolt can be fitted
11 - Hex socket-head bolt, 23 Nm
^ Slave cylinder to transmission
^ Self-locking
^ Always replace
12 - Bracket
^ For hose/pipe assembly
^ Fastened together to transmission with slave cylinder
^ Installing
^ Bolt onto transmission with clutch slave cylinder
13 - Push rod
^ Lubricate end of push rod with copper grease, e.g. Z 381 351 TE
Fig. 1 Removing shaft seal for input shaft:
- Lever out seal carefully with a screwdriver.
Note: Do not damage bearing surface on input shaft for shaft seal.
Fig. 2 Installing shaft seal for input shaft:
- Lightly oil outer circumference of seal.
- Fill space between sealing and dust lips with sealing grease G 052 128 A1.
- Pull a thin protective hose tightly onto splines of input shaft.
- Tapping in input shaft seal.
^ Standard insertion depth: 3.5 mm
^ Standard insertion depth: 4.5 mm
- Remove protective hose.
Fig. 3 Removing clutch release lever:
- Release bolt -1-, remove leaf spring - 2- and press back the detent arrow-.
- Remove clutch release lever A- together with release bearing -3-.
- Disengage the retaining latches of the release bearing at release lever.
Fig. 4 Installing clutch release lever:
- Before installing the clutch release lever, the contact surface of clutch slave cylinder push rod must be coated with a thin layer of copper paste.
- Insert clutch release lever -A- into the intermediate piece -C- and allow it to engage (detent -B- becomes visible).
- Insert leaf spring -item 7-,tighten retaining bolt -item 8 - to 25 Nm.
Fig. 5 Detaching slave cylinder from hose/pipe assembly:
Removing
- To remove the hose/pipe assembly, lever out clip -A- to the stop using a screwdriver. Only then can the hose/pipe assembly be pulled out.
Installing
- Press in clip -A- to stop.
- Push hose/pipe assembly into slave cylinder until it engages audibly.
- To check, pull on the hose/pipe assembly.
Fig. 6 Removing clutch slave cylinder:
- Remove bolt -arrow-, remove clutch slave cylinder rearward.
Note: Do not depress clutch pedal after removing slave cylinder.
Fig. 7 Installing clutch slave cylinder:
- Coat clutch slave cylinder with lithium grease G 052 150 A2.
- Engage bracket for hose/pipe assembly -3- at the slave cylinder -4-.
- When inserting the clutch slave cylinder into the mounting hole of the transmission housing, keep it as far as possible in line with the direction of operation of the push rod.
Notes:
^ If the clutch slave cylinder -4- is inserted off-fine there is a danger that the push rod will be guided past the clutch release lever.
^ When installing press in the clutch slave cylinder far enough so that the securing bolt can be fitted easily.
^ Replace securing bolt -2-.
- Tighten bracket for hose/line assembly together with slave cylinder on transmission.
Fig. 8 Coat clutch slave cylinder with grease before installing:
- Lightly lubricate contact surface for push rod at clutch release lever with copper grease, e.g. Z 381 351 TE.
- Before installing slave cylinder into transmission housing, lubricate area -a- on boot with lithium grease G 052 150 A2.
Fig. 9 Repairing release bearing with plastic ring:
In the case of release bearings with plastic ring it is possible that the plastic ring detaches from the release bearing during removal of the transmission. This does not signify that replacement of the release bearing is necessary.
- Cement the loose plastic ring to the bearing ring the with adhesive AMV 195 KD1 01 before installing the transmission.
Three rectangular lugs -arrows- on the plastic ring engage into recesses in the bearing ring.
Note: If the plastic ring has become embedded deeper than 0.5 mm in the bearing surface, the bearing ring must be replaced.