REMOVAL AND REFITTING CLUTCH

Removal and refitting clutch

Removal
− Remove the gearbox (see guidelines for
removal & refitting of gearboxes)
− Check gearbox primary shaft for damage
(damage to splines & nose for spigot bearing).
Check release bearing guide sleeve for impact
damage or wear.

− Unscrew clutch-mounting bolts diagonally to avoid

distortion.
− Remove clutch pressure and centre plate.

− Using a pair of pliers, lift the safety ring out of the

groove.
− Remove the release bearing from the clutch-
mounting bush.

Valeo clutch release bearing

− Remove the release bearing 1 from the thrust

collar 3 by squeezing the circlip 2 together

RA - B 7 2.10 - 1a
REMOVAL AND REFITTING CLUTCH

Refitting
− Before fitting the clutch, check that the crankshaft
oil seal and gearbox oil seal are not leaking.
Replace if necessary.
− If the spigot bearing is damaged, this is to be
renewed as well.

− Fit clutch disc onto centring mandrel and insert

into guide bearing.

Note: Before being fitted, every clutch disc

(even if it is new) is to be checked for trueness,
see Chapter 2.31 - 1.
In the case of a used clutch disc, any corrosion must
be removed from the hub splines.
Apply a light coating of all-purpose grease
MAN 283 Li-P2 to splines.

− Mount pressure plate. Secure mounting bolts

simultaneously by hand as tightly as possible.

− Tighten the mounting bolts diagonally to avoid

distortion to the required torque.
− Remove centring mandrel.

Note: If the bolts are not tightened correctly there is

a risk of the pressure plate housing cracking.

2.10 - 2a RA - B 7
 REMOVAL AND REFITTING CLUTCH

Mounting clamps for Valeo clutches

There are four mounting clamps around the edge of

the clutch pressure plate. These clamps must be
removed once the pressure plate has been fitted.

− Fit the release lever with the bearing block and

tighten mounting bolts to the prescribed torque.

Note: The only grease that may be used is multi-

purpose grease to MAN 283 Li-P2,
e.g. 09.15001-0020 (900g plastic container).
If the release bearing is coated with Teflon, the guide
sleeve must not be greased!

− Apply a thin coating of multi-purpose grease to

the sliding surface of the release bearing
− Using a small brush or a paintbrush, apply a thin
film of lubricant to the splines
− Lightly grease the inside of the spigot bearing and
end of gearbox primary shaft
− Move the release lever to its end position
− Arrange the release bearing on the guide sleeve

Release bearing for Valeo clutch

If an earlier release bearing is to be re-used, the

plastic ring 1 is, as before, to be pushed over the
circlip 2 before the bearing is fitted.

RA - B 7 2.10 - 3a
REMOVAL AND REFITTING CLUTCH

− Mount the gearbox on to the engine and tighten

mounting bolts to the prescribed torque.
− By moving the release lever to and fro by hand,
check whether the release bearing is engaged in
the clutch pressure plate.

Assembling the gearbox for the Valeo clutch

− Arrange the release bearing as usual on the guide

sleeve of the gearbox primary shaft.
− With the circlip 3 compressed, slide the gearbox
into the pressure plate 1 .

Note: The circlip 3 must be compressed by the

plastic ring 2 .

− As the gearbox is inserted, the pressure ring 3

forces the plastic ring 2 back and the circlip 1
engages in the pressure ring 3 .

Note: When inserting the gearbox, care must be

taken to ensure that the components are correctly
aligned, because if the circlip 1 is not correctly fitted
it can become displaced.

− Fit the clutch power pack and secure to the

release lever with a spring clamp.

2.10 - 4a RA - B 7
 REMOVAL AND REFITTING CLUTCH

− Arrange the wear indicator in such a manner that,

for a new clutch disc, the "MAX" mark lines up
with the marker arrow

RA - B 7 2.10 - 5a