Removal and installation the clutch release fork and clutch release bearing (Mercedes-Benz Sprinter 903)

When the clutch pedal is pressed, the clutch release bearing, under the action of the fork, presses on the ends of the petals of the diaphragm spring. The force is thus removed from the working surface of the pressure plate, and the driven disk rotates freely. The clutch release bearing is maintenance-free. Its malfunction can be determined by the characteristic sound when pressing the clutch pedal.

The clutch release bearing must be replaced as follows: (to replace the clutch drive parts, it is necessary to remove the gearbox):

• remove the clutch release bearing from the front gearbox cover (figure 180);

• move the clutch release fork first in the direction of arrow a (figure 181). Then, in the direction of arrow b, remove it from the ball pin and take it out of the clutch housing;
• thoroughly apply the recommended grease to the front cover guide bearing, the ball pin on the clutch housing and all areas on the clutch release fork that come into contact with the bearing. Use a long-lasting lubricant;
• place the clutch release fork onto the ball joint in the direction opposite to arrow b until the spring clip snaps into place;
• turn the fork in the direction opposite to the arrow a;
• apply grease to the inside of the bearing and to both cutouts on the back of the bushing;
• place the bearing on the guide on the front cover of the gearbox and turn it until its side cutout enters the fork body;
• install CP.

The bearing is checked as follows: turn the removed clutch release bearing by hand. The rotation should be free, smooth and silent.