02 Clutch
02 Clutch
02 Clutch
W25.10-1047-11
W25.10-1046-09
4 Flywheel 7 Clutch plate (at transmission end) 10 Clutch operator with release bearing
5 Clutch plate (at engine end) 8 Clutch pressure plate 11 Guide bearing
6 Intermediate ring with intermediate 9 Bolt
disk
Modification notes
1.9.06 Before installation of the new clutch pressure plate check Step 11
whether the diaphragm spring reeds are correctly seated
into the clutch bearing, added.
Removing
Clutch
950 589 00 61 00
Centering drift
1 Electrical connector
2 Electrical connector
W25.19-1011-11
3 Bolts
4 Retaining plate
W25.19-1012-11
Modification notes
16.5.11 Repair materials for clutch booster with plastic housing Operation step 3 *BR00.45-Z-1033-02A
added.
Remove/install
1 Disconnect electrical connector (2)
2 Disconnect electrical connector (1) from
clutch travel sensor (B2)
3 Remove bolts (3) from clutch travel sensor Installation: Insert screws (3) with
(B2) instant-set adhesive:
Clutch booster
© Daimler AG, 7/2/13, G/03/13, ar25.19-w-0100b, Remove/install clutch travel sensor Page 1 of 2
MODEL 930, 932, 933, 934 with CODE (GE2) Electronic drive control II MODEL 375.4, 930, 932, 933, 934, 940, 944 with CODE (GE3) Mercedes PowerShift MODEL 930, 932, 933, 934 with ...
Number Designation Model Model Model
374.607/ 930, 932, 940, 942,
691/695, 933, 934 943, 944
375.4
Repair materials
© Daimler AG, 7/2/13, G/03/13, ar25.19-w-0100b, Remove/install clutch travel sensor Page 2 of 2
MODEL 930, 932, 933, 934 with CODE (GE2) Electronic drive control II MODEL 375.4, 930, 932, 933, 934, 940, 944 with CODE (GE3) Mercedes PowerShift MODEL 930, 932, 933, 934 with ...
AR25.20-W-0300EA Clutch servo unit removal and installation 15.6.09
MODEL 930, 932, 933, 934
with CODE (IY2) Hydraulic fluid as per sheet 345.0
except CODE (GE2) Electronic drive control II
except CODE (GE3) Mercedes PowerShift
except CODE (GE7) Mercedes PowerShift 2
MODEL 942, 943, 958.4 with CODE (IY2) Hydraulic fluid as per sheet 345.0
MODEL 375.4, 940, 944
with CODE (IY2) Hydraulic fluid as per sheet 345.0
except CODE (GE3) Mercedes PowerShift
MODEL 374.6 with TRANSMISSION 715.5 with CODE (IY2) Hydraulic fluid as per sheet 345.0
W25.20-1020-09
W25.20-1055-12
Remove/install
© Daimler AG, 7/2/13, G/03/13, ar25.20-w-0300ea, Clutch servo unit removal and installation Page 1 of 2
MODEL 930, 932, 933, 934 with CODE (IY2) Hydraulic fluid as per sheet 345.0 except CODE (GE2) Electronic drive control II except CODE (GE3) Mercedes PowerShift except CODE (GE7) ...
Notes on hydraulic fluid as per Specification, AH00.40-N-0002-01A
Sheet 345.0
1 Drain reservoir pressure of compressed air
system
2 Separate clutch travel sensor connector (3)
3 Detach compressed air line bracket (12)
4 Detach compressed-air line (4) Counterhold at the banjo bolt (9) when
loosening the compressed air line (4).
*BA25.20-N-1010-01J
5 Unscrew the banjo bolt (9) *BA25.20-N-1003-01J
6 Remove locking device (5) from connector Collect hydraulic fluid which runs out with
(11) and detach hydraulic line (6) a suitable container.
7 Disconnect electrical connector (13)
8 Remove clutch servo unit (2) *BA25.20-N-1001-01J
9 Remove plunger (1) Installation: Clean ball head and guide of *BR00.45-Z-1001-06A
plunger (1) and grease with long-life grease.
10 Detach connector (11) Only when replacing the clutch booster
(2).
*BA25.20-N-1003-01J
11 Install in the reverse order
12 Bleed clutch operating system AR25.20-W-0070FA
Clutch booster
Repair materials
Number Designation Order number
BR00.45-Z-1001-06A Long-life grease A 000 989 63 51 11
© Daimler AG, 7/2/13, G/03/13, ar25.20-w-0300ea, Clutch servo unit removal and installation Page 2 of 2
MODEL 930, 932, 933, 934 with CODE (IY2) Hydraulic fluid as per sheet 345.0 except CODE (GE2) Electronic drive control II except CODE (GE3) Mercedes PowerShift except CODE (GE7) ...
AR25.20-W-0200G Remove and install clutch throwout lever 12.7.10
MODEL 933
MODEL 930, 932, 934 except CODE (G02) Torque converter clutch (WSK)
1 Release lever
2 Plunger
3 Bearing sleeve
4 Retaining ring
5 Washer
6 Bearing sleeve
7 Bearing axis
8 Guide rollers
W25.20-1081-05
Modification notes
18.3.10 Tightening torque for vehicles with code (GK8) Turbo Operation step 7 *BA25.20-N-1014-01B
clutch, added.
Removing
1 Remove engine, transmission or turbo clutch Select the procedure according to the
with transmission setup and accessibility.
2 Remove release lever (1)
3 Remove lifter (2) from release lever (1)
Checking
4 Check bearing bushing (3) of plunger (2) for If necessary, replace bearing bushing (3).
wear and damage
5 Check bearing bushings (6), bearing shaft If necessary, replace release lever (1) or
(7) and guide rollers (8) for wear and disassemble release lever (1) and replace
damage worn or damaged parts.
Install
6 Install lifter (2) into release lever (1)
7 Install release lever (1) Grease bearing points (arrows) lightly. *BR00.45-Z-1062-06A
Vehicles without code (GK8) Turbo *BA25.20-N-1001-01B
clutch
Vehicles with code (GK8) Turbo clutch *BA25.20-N-1014-01B
8 Install engine, transmission or turbo clutch
with transmission
Repair materials
Number Designation Order number
BR00.45-Z-1062-06A Lubricating grease, Olista Longtime, DB supply specification 6804.60 A 001 989 36 51 10
© Daimler AG, 7/2/13, G/03/13, ar25.20-w-0200g, Remove and install clutch throwout lever Page 1 of 1
MODEL 933 MODEL 930, 932, 934 except CODE (G02) Torque converter clutch (WSK)
AR25.20-W-3000B Remove/install clutch actuator 12.7.10
MODEL 930, 932, 934
with CODE (GE3) Mercedes PowerShift
with CODE (GK8) Turbo clutch
1 Clutch actuator
2 Vent valve
3 Cover
4 Electrical connector
5 Electrical connector
6 Compressed-air line
7 Banjo bolt
8 Banjo union (compressed air)
W25.20-1107-06
Removing
Danger! Risk of injury caused by body parts being Always remove the ignition key and vent the AS25.00-Z-0001-01A
trapped or crushed when working on the clutch actuator before removing clutch
pressurized clutch actuator actuator.
1 Withdraw ignition key
2 Drain reservoir pressure of compressed air
system
3 Disconnect electrical connectors (4, 5)
4 Remove clamp for compressed-air line (6)
from transmission
5 Detach air line (6) from banjo bolt (7) Counterhold at the banjo bolt (7) when
loosening the compressed air line (6).
6 Unscrew banjo bolt (7)
7 Unscrew cover (3) and press in the bleed pin As a result an adjustment is produced
in the vent valve (2) (arrow) between atmospheric pressure and the
pressure in the clutch actuator (1).
8 Remove clutch actuator (1)
Install
9 Adjust plunger of clutch actuator (1) Only when installing a new clutch or a AR25.20-W-3000-01B
new plunger.
*BA25.20-N-1011-01J
*930589002300
Bolt for adjusting device WF58.50-W-2520-01A
10 Press in the bleed pin in the bleed valve (2) Afterwards release the bleed pin and hold
(arrow) and simultaneously press the piston the piston rod of the clutch actuator (1)
rod of the clutch actuator (1) into the clutch securely in the retracted position.
actuator (1)
11 Install clutch actuator (1) *BA25.20-N-1012-01J
12 Screw down cover (3) securely
13 Install banjo bolt (7) with banjo union (8) *BA25.20-N-1008-01J
14 Fit air line (6) to banjo bolt (7) When tightening counterhold the banjo
bolt (7).
*BA25.20-N-1009-01J
15 Fit clamp for compressed-air line (6) to
transmission
16 Connect electrical connectors (4, 5)
930 589 00 23 00
Adjusting device
W25.20-0003-06
Modification notes
26.7.99 Programming EPS control unit Operation step 14
Remove/install
1 Switch off ignition
2 Open maintenance flap
Danger! Risk of poisoning caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A
brake fluid. Risk of injury caused by brake appropriately marked containers. Wear
fluid coming into contact with skin and eyes. protective clothing and eye protection when
handling brake fluid.
3 Extract brake fluid from master cylinder
expansion reservoir
Brake fluid notes All models AH42.50-P-0001-01A
4 Disconnect connector (X5)
5 Cut cable ties (arrows) Installation: Replace cable ties.
6 Take off cover (2)
7 Remove bolt (4) and detach connection of
circuit 30
8 Remove bolt (5) and disassemble ground
connection
9 Detach supply line (6) on master cylinder Collect escaping brake fluid using a
suitable container.
Installation: The supply line (6) must
engage securely in the rubber grommet of
the master cylinder.
10 Remove retainer (7) and detach hydraulic In the event of sluggishness grasp
line (8) hydraulic line (8) at the front on the metal
piece using suitable pliers, loosen by light
rotary motions and press downwards.
Collect escaping brake fluid using a
suitable container.
11 Detach electromotive clutch (1) from bracket *BA25.20-N-1004-01B
12 Install in the reverse order
13 Bleed clutch operating system AR25.20-W-0070B
14 Teach in EPS control unit AR54.21-W-0007A
© Daimler AG, 7/2/13, G/03/13, ar25.20-w-0110a, Remove/install electromotive clutch (EMK) Page 1 of 2
ENGINES 541.92, 542.92 with CODE (GE1) Electronic drive control
Number Designation Engine 541.9,
542.9
© Daimler AG, 7/2/13, G/03/13, ar25.20-w-0110a, Remove/install electromotive clutch (EMK) Page 2 of 2
ENGINES 541.92, 542.92 with CODE (GE1) Electronic drive control
AR25.20-W-0100D Remove/install master cylinder 15.6.09
MODEL 930, 932, 933, 934
except CODE (GE2) Electronic drive control II
except CODE (GE3) Mercedes PowerShift
except CODE (GE7) Mercedes PowerShift 2
W25.20-1073-12
7 Expansion reservoir
8 Screw
9 Master cylinder
10 Fuse
11 Hydraulic line
W25.20-1074-12
Remove/install
Danger! Risk of poisoning caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A
brake fluid. Risk of injury caused by brake appropriately marked containers. Wear
fluid coming into contact with skin and eyes. protective clothing and eye protection when
handling brake fluid.
Brake fluid notes AH42.50-P-0001-01A
Notes on hydraulic fluid as per Specification, AH00.40-N-0002-01A
Sheet 345.0
1 Fold back floor covering (6)
2 Remove left footwell cover (1)
3 Remove center footwell cover (2)
Repair materials