Clutch Repairs (465) Copyright GEDORE Automotive GmbH, Germany. formerly

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1 Copyright GEDORE Automotive GmbH, Germany (465) -01

2 KL KA Clutch Tool Set (SAC), in a Plastic Storage Case (Pat.) Suitable for Self-Adjusting Clutches (with 6 and 8 bolt holes); e.g. on VW-Audi, BMW, Mercedes, Volvo, Opel/Vauxhall, Renault etc. Product Demo Video The KL KA clutch tool set is indispensable for the professional removal and installation of Self-Adjusting Clutches (SAC). Correct removal and installation of this type of clutch is virtually impossible without the use of our tool set. Using the wrong tool risks damaging or distorting the clutch. This will result in incorrect separation or grabbing of the clutch. Distorted or incorrectly mounted clutches are defective and must always be replaced. The KL KA tool set prevents damage to the SAC when removing and installing it. Also, the risk of distorting the adjuster ring in the clutch pressure plate is eliminated using this tool. The newly developed clutch aligner KL enables clutch discs to be centred also on vehicles that do not feature a pilot bearing in the crankshaft. The two clamping-/centring elements ensure, on the first clamping element (Ø 15-28mm) the accurate centring in the clutch disc, and on the second element (Ø 12-28mm) the accurate centring in the pilot bearing, respectively the crankshaft bore. Even clutches on engines where the crankshaft bore Ø is greater than the clutch disc hub Ø can be aligned neatly and accurately thanks to this tool. Advantages: Enables the clutch pressure plate to be pretensioned during removal and installation (important as a means of avoiding distortion on the clutch). Enables the clutch disc to be centred relative to the pilot bearing or to the pressure plate. Enables the adjuster ring to be reset, when used in conjunction with reset tool KL Example of Clutch (SAC) Removal 1. Insert clutch aligner into clutch and tighten it. 2. Unscrew 3x clutch pressure plate fastening screws. Replace with threaded bolts. Install clutch pre-compressor. 3. Compress diaphragm spring. Unscrew remaining fastening screws. Release pressure on diaphragm spring. 4. Remove knurled nuts and clutch pre-compressor. Remove clutch aligner and threaded bolts. 5. Remove clutch pressure plate. 6. Remove clutch disc. -02 (466) Copyright GEDORE Automotive GmbH, Germany

3 KL KA Clutch Tool Set (SAC), in a Plastic Storage Case (Pat.) Resetting the Adjuster Ring. Install clutch pressure plate without clutch disc. 8. Screw in threaded bolts. Mount clutch pre-compressor. 9. Compress diaphragm spring. 10. Insert reset tool. Turn back adjuster ring. Example of Clutch (SAC) Installation 11. Release pressure on diaphragm spring. Remove reset tool. 12. Remove knurled nuts, clutch pre-compressor and threaded bolts. Remove clutch pressure plate. 13. Insert clutch aligner and clutch disc into flywheel. Tighten clutch aligner. 14. Position clutch pressure plate. 15. Screw down threaded bolts. Mount clutch pre-compressor. 16. Compress diaphragm spring. Screw in fastening screws. Release pressure on diaphragm spring. 1. Remove knurled nuts, clutch pre-compressor and threaded bolts. Remove clutch aligner. 18. Screw in and tighten down the clutch pressure plate fastening screws. Copyright GEDORE Automotive GmbH, Germany (46) -03

4 KL KA Application Video KL KA Clutch Tool Set (SAC), in a Plastic Storage Case (Patented) Suitable for Self-Adjusting Clutches (with 6 and 8 bolt holes); e.g. on VW-Audi, BMW, Mercedes, Volvo, Opel/Vauxhall, Renault etc. The KL KA clutch tool set is indispensable for the professional removal and installation of Self-Adjusting Clutches (SAC). PM 0 - Tools for Clutch Repairs KL KA Clutch Tool Set (SAC), in a Plastic Storage Case KL Clutch-Pretensioning Tool (3-hole pitch) 1 KL Reset Tool 1 KL Set of Clutch-Centring Pins (3-pc) 1 KL Clutch Aligner 1 KL Upgrade Kit (4-hole pitch) 1 KL Plastic Storage Case 1 KL Clutch-Pretensioning Tool KL Clutch-Pretensioning Tool (Base Tool) 1 KL Knurled Nut 1 KL Threaded Bolt, M6 1 KL Threaded Bolt, M 1 KL Threaded Bolt, M8 1 Self-adjusting clutch (SAC) Scope of Delivery KL Set of Clutch-Centring Pins KL Clutch-Centring Pin, Ø 23mm 1 KL Clutch-Centring Pin, Ø 28mm 1 KL Clutch-Centring Pin, Ø 32.5mm 1 Align clutch disc KL Clutch Aligner KL Guide Tube (complete) 1 KL Centring Pin, Ø 12mm 1 KL Centring Pin, Ø 14mm 1 KL Centring Pin, Ø 15mm 1 KL Clamping Cone, Size 2, 22mm 1 KL Cone Adaptor 1 KL Set of Clamping Elements, Ø 20mm 1 KL Sliding Cone, Ø 15mm, 40mm long 1 KL Sliding Cone, Ø 15mm, 6mm long 1 KL Sliding Cone, Ø 15mm, 5mm long 1 KL Sliding Cone, Ø 18mm, 5mm long 1 KL Sliding Cone, Ø 18mm, 6mm long 1 Position clutch pressure plate Pretension clutch KL Upgrade Kit (4- hole pitch) for KL K and KL K KL Knurled Nut 1 KL A Knurled Nut 1 KL Threaded Bolt, M6 1 KL Threaded Bolt, M 1 KL Threaded Bolt, M8 1 KL Base Plate, with 4-hole pitch 1 Turn back adjuster ring -04 (468) Copyright GEDORE Automotive GmbH, Germany

5 KL Clutch-Centring Pin, Ø 26.5mm, BMW/Audi KL Applicable to BMW and Audi. Designed to align the clutch disc before the re-installation of a pretensioned selfadjusting clutch (SAC). Can also be used to align new and already pretensioned SACs. KL Clutch-Centring Pin, Ø 26.5mm KL Applicable to BMW E36, E39, E46, E8 equipped with a S5D-250G gearbox. This tool is used for centring the clutch disc before the re-installation of a pretensioned self-adjusting clutch (SAC). Can also be used to align new and already pretensioned SACs. KL Clutch-Centring Pin, Ø 32.5mm KL Suitable for the BMW vehicles equipped with a GS6-53DG gearbox and S65 (V8) or S85 (V10) engine: E92 (M3), E60 (M5) and E63 (M6). This tool is used for centring the clutch disc before installing or re-installing a selfadjusting clutch (SAC). KL Clutch-Centring Sleeve, Ø 32.5mm, BMW KL Suitable for BMW vehicles with a N54B30 engine, e.g. E90/E91/E92/E93 (335i) This tool is used for centring the clutch disc before installing or re-installing a selfadjusting clutch (SAC) Inner Ø: Outer Ø: 15mm 32.5mm KL Clutch Centring Sleeve Ø 32.5 mm KL A Hex screw M5x45mm 1 KL Centring sleeve 1 KL Pin-Type Face Spanner, Ø mm, Pin Ø 5mm KL Suitable for VW-Audi, Fiat etc. Designed to remove the pre-tension ring when installing a new SAC (Self-Adjusting Clutch) on Audi, Fiat etc. Ø: mm Pin Ø: 5mm Pin height: 6mm Overall length: 215mm Weight: 300g Copyright GEDORE Automotive GmbH, Germany (469) -05

6 KL KL Upgrade Kit (4-hole pitch) for KL K and KL K Base plate with 4-hole pitch. Required for pretensioning the clutch pressure plate before removing and installing an SAC featuring 8 bore holes. KL Upgrade Kit (4- hole pitch) for KL K and KL K KL Knurled Nut 1 KL A Knurled Nut 1 KL Threaded Bolt, M6 1 KL Threaded Bolt, M 1 KL Threaded Bolt, M8 1 KL Base Plate, with 4-hole pitch 1 KL KL Clutch Aligner (Patented) Suitable for Self-Adjusting Clutches (SAC). Essential tool for vehicles without a pilot bearing in the crankshaft. The newly developed clutch aligner KL enables clutch discs to be centred also on vehicles that do not feature a pilot bearing in the crankshaft. The two clamping-/centring elements ensure, on the first clamping element (Ø 15-28mm) the accurate centring in the clutch disc, and on the second element (Ø 12-28mm) the accurate centring in the pilot bearing, respectively the crankshaft bore. Even clutches on engines where the crankshaft bore Ø is greater than the clutch disc hub Ø can be aligned neatly and accurately thanks to this tool. KL Clutch Aligner KL Guide Tube (complete) 1 KL Centring Pin, Ø 12mm 1 KL Centring Pin, Ø 14mm 1 KL Centring Pin, Ø 15mm 1 KL Clamping Cone, Size 2, 22mm 1 KL Cone Adaptor 1 KL Set of Clamping Elements, Ø 20mm 1 KL Sliding Cone, Ø 15mm, 40mm long 1 KL Sliding Cone, Ø 15mm, 6mm long 1 KL Sliding Cone, Ø 15mm, 5mm long 1 KL Sliding Cone, Ø 18mm, 5mm long 1 KL Sliding Cone, Ø 18mm, 6mm long 1-06 (40) Copyright GEDORE Automotive GmbH, Germany

7 KL K Dual Mass Flywheel Wear-Testing Tool (For Testing On The Vehicle) KL K Universally suitable for vehicles equipped with Dual Mass Flywheel (DMF). Indispensable tool for the quick and professional wear tests of Dual Mass Flywheels (DMF). Tests can be performed directly on the vehicle with the clutch removed. The test involves checking the rock allowance (axial play) and the freeplay angle (torsion of the secondary flywheel against the primary flywheel until the tension of the spring can be felt). Note: As a rule, Dual Mass Flywheels should always be checked for wear and damage when replacing a clutch. Professional tests are essential as Dual Mass Flywheels that are deteriorated or worn can damage the new clutch as well as the gearbox and drive train. Advantages: Universal application. Substantial time savings. The tool is easy to operate. Professional and accurate working. KL KL KL K Dual Mass Flywheel Wear-Testing Tool (on-vehicle tests) KL K Dual Mass Flywheel Wear-Testing Tool 1 KL Torque Angle Gauge 1 KL Dial Gauge, Ø 58mm 1 KL K Dual Mass Flywheel Wear-Testing Tool (without Dial Gauge, Torque Angle Gauge) KL Dual Mass Flywheel Wear Testing Tool (for testing on the vehicle) 1 KL Plastic Storage Case 1 KL Dual Mass Flywheel Wear-Testing Tool (on-vehicle tests) KL Slotted Bar with Fixing Device 1 KL Stand for Dial Gauge 1 KL Flywheel Locking Tool 2 KL Slotted bar with fixing device KL Slotted Bar with Protective Handle 1 KL Special Screw, M6 2 KL Special Screw, M 2 KL Special Screw, M8 2 KL Shoulder Nut, M8 4 KL Set Screw, M8x80 (pointer) 1 Measuring the freeplay angle by number of teeth Checking the rock allowance Measuring the freeplay angle with degree gauge KL Dial Gauge, Ø 58mm KL Spindle and clamping shank made of stainless steel, design and measurement accuracy according to DIN 88-A. Graduation: 0.01mm Measuring Range: 10mm Housing -Ø: 58mm 1 pointer revolution: 1mm Clamping shank Ø: 8mm Copyright GEDORE Automotive GmbH, Germany (41) -0

8 Tools for Double Clutch (Pat.) KL K Base Toolkit for Double Clutch Universally applicable to VW-Audi, Seat, Škoda, Renault and Ford passenger cars with dry double clutch systems. For example: VW-Audi 1st generation transmissions 0AM (until 5/2011), 2nd generation transmissions 0AM (from 6/2011 onwards); Renault DC4 and Ford DPS6 etc. Having always the right specialist tool at hand is essential for carrying out professional repairs to double clutch systems and to avoid costly damage in the first place. Used in conjunction with the respective vehicle-specific upgrade kit, the KL K base toolkit for double clutches allows for professional repairs to all LuK* Double Clutch Systems (dry double clutches) that are currently available on the market. The forward-looking modular concept allows for continuous enhancement of the KL K base toolkit for double clutches with vehicle-specific upgrade kits, thus making it applicable also to future double clutch systems. *LuK, a member of the Schaeffler Group, is an internationally renowned supplier of clutch- and transmission systems, torque converters and dampers to the Automobile Industry and Aftermarket. KL K Upgrade Toolkit for Double Clutch, VW KL K Upgrade Toolkit for Double Clutch, Renault Applicable to VW-Audi, Seat and Škoda vehicles with dry double clutch systems. For example: 1st generation DSG transmissions 0AM (until 5/2011) and 2nd generation DSG transmissions 0AM (from 6/2011 onwards). The KL K upgrade toolkit for double clutch is designed to be used in conjunction with the KL K (LuK ) base toolkit, thus allowing for the professional dismantling, assembly and adjustment of dry double clutch systems found on VW-Audi, Seat and Škoda vehicles. KL K Upgrade Toolkit for Double Clutch, Ford KL K Reset Toolkit for Double Clutch Applicable to Renault vehicles with dry double clutch systems, e.g. with DC4 transmission. The KL K upgrade toolkit for double clutch is designed to be used in conjunction with the KL K (LuK ) base toolkit, thus allowing for the professional dismantling, assembly and adjustment of dry double clutch systems found on Renault vehicles. KL K Update Toolkit for Double Clutch Applicable to Renault and Ford passenger cars equipped with a 6-speed double clutch DC4 transmission (Renault) and DPS6 transmission (Ford) respectively. The reset toolkit upgrades the base toolkit for double clutch KL K (LuK ). The toolkit is designed to professionally reset/ re-enable the transport lock of a double clutch that has been removed and is to be re-installed, for example, after repairs to the gearbox. Applicable to Ford vehicles with dry double clutch systems, e.g. with DPS6 transmissions. The KL K upgrade toolkit for double clutch is designed to be used in conjunction with the KL K (LuK ) base toolkit, thus allowing for the professional dismantling, assembly and adjustment of dry double clutch systems found on Ford vehicles. Note: All new double clutches for DC4 (Renault) and DPS6 (Ford) double clutch transmissions come provided with a transport lock. This means that no additional work needs to be carried out before the installation of a new clutch and, consequently, the KL reset toolkit is not necessary. The KL K update toolkit is designed to complement the previous LuK toolkit for double clutch (LuK ), so that the contents includes all the tools of the current KL K base toolkit for double clutch and KL K upgrade toolkit for VW. -08 (42) Copyright GEDORE Automotive GmbH, Germany

9 KL Clutch Aligner For Hub Ø: 15-28mm. (Universal) Thanks to the parallel expansion technique it is now possible to align the clutch disc either relative to the clutch pressure plate (on vehicles that do not feature a pilot bearing in the crankshaft) or, via the pilot bearing relative to the flywheel. KL KL Clutch Aligner KL Clutch Aligner for Passenger Cars 1 KL Centring Sleeve Set 1 KL Plastic Storage Case 1 Advantage: The newly-developed parallel expansion technique with self-centring feature ensures that the tool remains accurately positioned in the axis of the clutch disc hub throughout the whole alignment processs, thus allowing for precise centring of the clutch disc. KL Clutch Aligner for Passenger Cars (Universal) Suitable for clutch hub Ø: 15-28mm. Thanks to the parallel expansion technique, it is now possible to align the clutch disc either relative to the clutch pressure plate (on vehicles that do not feature a pilot bearing in the crankshaft) or, via the pilot bearing relative to the flywheel. KL Clutch Aligner for Passenger Cars KL Clutch Aligner Base Tool 1 KL Clamping Segment Set, 19mm 1 KL Clamping Segment Set, 24mm 1 KL Advantage: The newly-developed parallel expansion technique with self-centring feature ensures that the tool remains accurately positioned in the axis of the clutch disc hub throughout the whole alignment processs, thus allowing for precise centring of the clutch disc. KL Clutch Aligner, Vans/Small Lorries (LGV) Suitable for vans and small lorries (LGV) with a hub Ø of from 24-36mm. This clutch aligner is indispensable for the quick and easy centring of the clutch disc/ clutch discs. The centring takes place via the pilot bearing in the crankshaft. KL KL Clutch Aligner, Vans/Small Lorries (LGV) KL Centring Sleeve Set 1 KL Clutch-Centring Pin 1 KL R Clutch Aligner, Renault Intended for use on vans and small lorries (LGV) with a hub Ø of from 23-35mm. An ideal tool for Renault. This clutch aligner is indispensable for the quick and easy centring of the clutch disc/ clutch discs. The centring takes place via the pilot bearing in the crankshaft. KL R KL R Clutch Aligner, Renault KL Centring Sleeve Set 1 KL R Clutch-Centring Pin 1 Copyright GEDORE Automotive GmbH, Germany (43) -09

10 KL-0201 KL-0201 Clutch Alignment Tool Intended for use on: VW Golf vehicles equipped with litre engines. Allows the clutch driving plate to be aligned relative to the flywheel. KL-0202 Clutch Alignment Tool Intended for use on VW engines featuring 16 valves. Allows the clutch driving plate to be aligned relative to the flywheel. KL KL Clutch Cable Clamp Suitable for VW Golf (II and III), etc. When replacing a clutch, the self-adjusting clutch cable needs to be secured with the KL clamp before removing the clutch. Failure to do so will lead to damage to the clutch cable which, as a result, will have to be renewed completely. KL A KL A Pliers for Clutch Master Cylinder Piston Rod KL Applicable to: Vauxhall/Opel: Astra-J, Signum, Vectra-C; Audi: A1 (8X), A3 (8P), A4 (B), A6 (C6); VW: Golf (1K1), Passat (3B6), Eos (1F) etc. The pliers are designed to release the clutch master cylinder piston rod from the clutch pedal quickly and with ease. Very useful tool when removing a clutch master cylinder/pedal support bracket. Min. opening distance between jaws: Max. opening distance between jaws: Overall length: KL Set of Clamps (3-pc.) 3mm 60mm 290mm Suitable for Opel/Vauxhall. Used to fix the pretensioned clutch pressure plate. KL KL Clutch Assembly Ring (Plastic), Opel/Vauxhall/Saab Suitable for Opel/Vauxhall and Saab passenger cars. For Ø mm Assembly aid to secure and keep the pretensioned diaphragm spring on the clutch pressure plate. -10 (44) Copyright GEDORE Automotive GmbH, Germany

11 KL Inner Bearing Extractor Set Universally applicable to passenger cars. Includes collet chucks with Ø 10-20mm. This set allows for the quick and professional replacement of pilot-/guide bearings, alternator bearings, etc. The collets are manufactured from special high-grade steel to ensure proper functioning of the tool. KL KL Inner Bearing Extractor Set KL Spreader, 5mm 1 KL Spreader, 6mm 1 KL Slide Weight 1 KL Collet Chuck, 10mm 1 KL Collet Chuck, 12mm 1 KL Collet Chuck, 15mm 1 KL Collet Chuck, 1mm 1 KL Collet Chuck, 20mm 1 KL Plastic Storage Case 1 KL Inner Bearing Extractor Set Applicable to passenger cars and lorries. Includes collet chucks with Ø 10-30mm. This set allows for the quick and professional replacement of pilot-/guide bearings, alternator bearings, etc. The collets are manufactured from special high-grade steel to ensure proper functioning of the tool. KL KL Inner Bearing Extractor Set KL Inner Bearing Extractor Set 1 KL Collet Chuck, 25mm 1 KL Collet Chuck, 2mm 1 KL Collet Chuck, 30mm 1 KL Internal Extractor Set with Slide Hammer (0.8kg) Can be used for a wide range of applications, for example, for clutch pilot bearings. This tool set allows for the removal of bearings, bearing shells and bushings, for example, from blind boreholes. KL Internal Extractor Set with Sliding Hammer (0.8kg) KL Collet Chuck, 12-15mm 1 KL Collet Chuck, 15-19mm 1 KL Collet Chuck, 19-25mm 1 KL Adaptor for Injector Nozzle Puller, M10 1 KL Slide Hammer Puller (base tool) 1 KL KL-0110 A Holding Wrench (Universal) KL-0110 A Universal application. Used for locking flywheels. Length: Weight: 250mm 0.5kg Copyright GEDORE Automotive GmbH, Germany (45) -11

12 KL A KL A Flywheel Locking Tool (adjustable) This tool is designed to lock the flywheel with the gearbox removed. The tool is axially and radially adjustable and, thus, almost universally applicable - simply by using different stud bolts. Bolt Ø: Bolt distance: 8.5mm 92-10mm KL KL Multi-Spline Sockets The special socket enables the drive shaft fixing screws to be loosened from the differental flange quickly and easily from the outside. Not intended for use with impact wrenches. Advantages: Substantial time savings. KL Multi-Spline Socket, XZN M8, 800mm Suitable for VW-Audi, etc. Size (waf): XZN M8 Drive: 1/2" Length: 800mm KL Multi-Spline Socket, XZN M10, 800mm Suitable for VW Golf IV etc. Size (waf): XZN M10 Drive: 1/2" Length: 800mm KL Multi-Spline Socket, XZN M12, 800mm Suitable for VW T4, Touareg etc. Size (waf): XZN M12 Drive: 1/2" Length: 800mm KL Multi-Spline Socket, XZN M14, 800 mm Suitable for VW T4, Touareg etc. Size (waf): XZN M14 Length: 800mm Drive: 1/2" -12 (46) Copyright GEDORE Automotive GmbH, Germany

13 KL Flexible Multi-Spline Bit Socket, XZN M10 KL Suitable for VW-Audi, for example VW Golf IV, Passat 3C etc. For the quick and easy removal and installation of drive shafts. The special design of the socket allows you to easily access the fastening screws that are sometimes difficult to reach. The tool is not designed for use with an impact wrench. Advantages: Substantial time savings. Size (waf): XZN M10 Drive: 3/8" Length: 128mm KL Puller for Clutch Release Shaft, Fiat Ducato KL Suitable for Fiat Ducato vehicles (1994 onwards) equipped with a pull-type clutch. Intended for the removal of clutch release shafts. This tool is necessary when the gearbox needs to be removed, for example when replacing the clutch, or for gearbox repairs. KL Removal Mandrel for Clutch Release Bearing KL For use on Fiat Ducato vehicles (from 1994 onwards) equipped with a pull-type clutch. In order to remove the release bearing from the pressure plate, the circlip needs to be pretensioned with the aid of the KL removal mandrel. Accessories (on demand): 1993 U-20 CODE: Reversible ratchet 3093 U-20 CODE: Reversible ratchet 3/8 200mm Copyright GEDORE Automotive GmbH, Germany (4) -13

14 KL KL Engine Lifter, VW T4 Suitable for VW T4 Vans (short front end). Designed to lift and pull the engine/gearbox assembly forwards. For the removal and installation of the clutch, respectively the gearbox, on VW T4 vehicles, it is essential to support the engine with the KL engine lifter. After undoing all mounting bolts and connections as well as loosening the exhaust flange, lift and pull/push the engine forwards to the right front side until the pulley of the crankshaft almost touches the subframe. Only then will it be possible to remove the gearbox and change the clutch. Advantages: Easy mounting of the engine lifter to the vehicle. Support of upper wishbones by retaining wedges for removal of the drive shaft. Support and correct positioning of the engine to any desired position. Easy removal and installation of gearbox and clutch. Suitable for 4- and 5-cylinder engines. Safety fixture avoids caught-in fingers in the tool s support. Length: Height: Width: Weight: 80mm 365mm 230mm 21.2kg Note: Removal and installation of gearbox and clutch without engine lifter KL is a dangerous procedure. Centring the clutch can be carried out with the aid of the KL tool. KL Engine Lifter, VW T4 KL Lifting Frame 1 KL Support 1 KL Retainer for 4-CylinderEngines 1 KL Retainer for 5-Cylinder Engines 1 KL Set of SupportingWedges (2-pc.) 1 KL KL Support, VW T4 Suitable for: VW T4 model 1995 onwards (extended bodywork length). Designed to lift and pull the engine/gearbox assembly forwards. The support is used in conjunction with the engine lifter KL (48) Copyright GEDORE Automotive GmbH, Germany

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