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Clutch operation complaints

SERVICE INFORMATION
Bulletin Nbr: 410-1976 edition 2
Date: ........... June 1998
Market: all
Clutch operation complaints


Cars affected

LHD cars with manual gearbox M94-97

Background

In some cars, the clutch cable may malfunction which results in problems when operating the clutch. A malfunctioning cable may cause customer complaints such as increased clutch pedal effort or improper freeplay. In case of customer complaints, the following should be done.

Parts required

49 01 724 Clutch cable 4-cyl

49 01 732 Clutch cable V6

87 81 718 Silicone grease (one package sufficient for 5 cars)

44 90 249 Bracket (only if necessary)

79 72 805 Screw (only if necessary)

Return of material in stock

US: Return P/N 44 90 181 and 44 90 199 to your servicing PDC by June 15, 1998.

Procedure


1. Remove the clutch cable, see Service Manual 4:1. Manual transmission, Clutch operation, clutch wire dismantling/assembly.


2. Lubricate the clutch cable mountings by the clutch pedal and clutch arm with silicone grease 87 81 718.

3. Fit the new clutch cable, see 4. Power transmission, Manual gearbox, Clutch cable, Adjustment/replacement.

Important

The adjusting mechanism must be completely pressed in towards the firewall for the adjustment to function. Also note that the locating bracket (figure 4) is critcal to the correct adjustment and operation of the clutch and cable.


4. Inspect and replace bracket, part No. 44 90 249 and screw, part No. 79 72 805, if damaged. Check that the bracket is centered on the sleeve and that the sleeve is fitted according to the measurement in the illustration. Tighten the bracket to the body.

5. Check that there is free play in the clutch pedal.

6. Check that the clutch cable follows the upper curve (6A) if the clutch is new. There is a need for some excess, since the cable casing is stretched when the clutch is worn and the adjusting mechanism will compensate for this. When the clutch is worn, the cable will follow the lower curve (6B).

7. Make sure that the clutch cable has a smooth routing without any kinks or sharp bends.


Warranty/Time Information

Object code: 41281

Fault/Reason code: 23

Location code: 9

Warranty type (US): 01

Repair/Action code: 01

Labour Operation (US): 41281

Time: 0.7