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Version 02 | Valid from 12.2020
Special tools for Service, Inspection and Assembly
V2
Contents SACHS Special tools
Contents V2General Information V3SACHS special tools V4 Clutch centering tool kit for trucks V5Assembly tool kit clutches/fl ywheels for passenger car and LCV V6Inspection tool for dual-mass fl ywheel for passenger cars andlight commercial vehicles V7Lateral run-out tester for clutches and centering pin for passenger cars V8Lateral run-out tester for clutchesfor trucks V9Shock absorber assembly tool kit for passenger cars andlight commercial vehicles V10Cleaning system for electric contact surfaces V11
V3
General Information
The products listed inthis catalog must beinstalled in a workshopby qualified personnelonly.
This catalog is only an excerpt of our product range – our electronic media provide a complete overview.
To fulfill your request, we need the complete order number, for example:
Assembly tool kit for passenger car and LCV clutches/flywheels 4200 080 561
In case of doubt, please provide the type description and the model year of the vehicle for which the desired item is intended.
All rights reserved. Duplication or joint use of this catalog, even in extracts, for the creation of your own catalog is prohibited, unless explicit consent is given.
Replacement part numbers from the vehicle manufacturer serve only for purposes of comparison. Use of such information in invoices to the vehicle owner is not permitted.
Current terms and conditions are available at aftermarket.zf.com/documents
Our Catalogs Online and digital (Please click here)
Version 03 | Valid from 09.2019
Shock absorbers for Pc
WebCatOnline Catalog
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V4
SACHS special tools – Efficiency andknow-how for your workshopEach new vehicle generation comes with ever higher demands not only on individual vehicle components, but also on expert performance of all work on the vehicle.
ZF Aftermarket offers an extensive range of high-quality special
tools for workshops under the SACHS brand.
All SACHS special tools come with extensive operating instructions. Technical training courses available from ZF Aftermarket use SACHS special tools wherever appropriate.
Whatever your task: assembly, inspection, service or repair
work – SACHS special tools are the perfect solution for effi cient,
smooth performance that saves you time and money.
Clutch centering tool kit for trucksUniversally suitable for commercial vehicles with single and twin plate clutches.
The clutch centering tool kit for trucks ensures fast,
easy centering of truck clutch plates. Adjustment is
centered via the guide bearing in the crankshaft.
V5
Included in the package Quantity | unit
4200 080 562 Clutch centering pin size 1 – Ø 36,0 – 45,0 mm 1 pce
Clutch centering pin size 2 – Ø 42,0 – 52,0 mm 1 pce
Centering piece – Ø 20,0 mm 1 pce
Centering piece – Ø 25,0 mm 1 pce
Centering piece – Ø 27,0 mm 1 pce
Centering piece – Ø 30,0 mm 1 pce
Operating instructions 1 pce
Plastic carry case 1 pce
V6
Assembly tool kit clutches/flywheels for passenger car and LCVThe clutch tool kit is ideal for disassembling and installing XTend and conventional clutches as well as for centering clutch disks.
The clutch tool kit prevents not only unwanted adjustment of
the XTend clutch but also housing distortion of conventional
clutches during assembly.
The centering tool is ideal for centering the clutch disk, also in
engines without a guide bearing in the crankshaft or with larger
crankshaft bore diameters than the clutch disk hub diameter.
The two clamping/centering elements guarantee precise
centering in the clutch disk with one clamping element, and
precise centering in the guide bearing or crankshaft bearing
with the other clamping element.
Included in the package Quantity | unit
4200 080 561 Clutch pre-tensioning device 1 pce
Knurled nuts 4 pcs
Threaded bolts M6, M7 and M8 per size 4 pcs
Knurled nuts 4 pcs
Clutch centering tool (clamping cone 15.0 / 22.0 mm, centering pins Ø 12.0 / 14.0 / 15.0 mm, set of clamping
segments Ø 15.5 / 20.0 mm, sliding cones Ø 15.0 mm | 40.0 / 67.0 / 75.0 mm and Ø 18.0 mm | 67.0 / 75.0 mm) per size 1 pce
Clutch centering pins Ø 15,0 mm | 23,0 / 26.5 / 28,0 / 32,5 mm per size 1 pce
Clutch centering sleeve Ø 32,5 mm 1 pce
Base plate with 4-hole division 1 pce
Face wrench 1 pce
Molybdenum disulfide paste 1 tube
Operating instructions 1 pce
Plastic carry case 1 pce
Inspection tool for dual-mass flywheel for passenger car and LCVThe dual-mass flywheel inspection tool enables easy checking of a dual-mass flywheel (DMF) in installed or disassembled condition.
You can use it to check e.g. the free travel of the torsional
damper and the evenness of its spring force or the axial
bearing conditions and the displacement travel of the radial
bearing site.
Please note: this tool is only designed for SACHS dual-mass
flywheels from ZF. Due to their design, DMFs with a transfer
plate and DMFs for dual clutch transmissions can not be
checked with the tool.
V7
Included in the package Quantity | unit
4200 080 563 DMF supporting fixture (profile rail with stop, base plate and holder as well as 2 slot nuts in sizes M10 and M9) 1 pce
Cap screws M8 x 12,0 mm 2 pcs
Spacer bolts M6, M7, M8 per size 2 pcs
Cap screws M9 x 30 mm 2 pcs
Cap screws M10 x 30 mm 2 pcs
Lever with brackets 1 pce
Lever with extension 1 pce
Flywheel blocking tools 2 pcs
Operating instructions 1 pce
Plastic carry case 1 pce
V8
Lateral run-out tester for clutches and centering pin for passenger carsFor clutch disks with an outside diameter of up to 240 mm.
To ensure correct functioning of the clutch disk in the vehicle after assembly, it is essential to test the lateral run-out of the new clutch disk before assembly.
The maximum permissible deviation of 0.5 mm must not be
exceeded. The tool kit contains all the parts required for this
test.
For clutch disks with an outside diameter of more than
240 mm, use the SACHS lateral run-out tester for commercial
vehicles (article number 4200 080 580).
Included in the package Quantity | unit
4200 080 560 Basic rack 1 pce
Guide pin with pre-assembled hexagon socket screw 1 pce
Small and large thrust pieces per size 1 pce
Extension for small thrust piece 1 pce
Guide pieces Ø 12,0 to 19,0 mm per size 1 pce
Clamping bar 1 pce
Small and large mandrels per size 1 pce
Dial gage 1 pce
Holder for dial gage 1 pce
Measuring sensor 1 pce
Box wrench 1 pce
Alignment fork 1 pce
Operating instructions 1 pce
Lateral run-out tester for clutches for trucksFor clutch disks with an outside diameter of more than 240 mm.
To ensure correct functioning of the clutch disk in the vehicle after assembly, it is essential to test the lateral run-out of the new clutch disk before assembly.
The maximum permissible deviation of 0.5 mm must not be exceeded. The tool kit contains all the parts required for this test.
V9
Included in the package Quantity | unit
4200 080 580 Fixing plate 1 pce
Fixing plate with guide pin 1 pce
Support pins with wing nuts 4 pcs
Basic rack 1 pce
Clamping screws 3 pcs
Bushing 1 pce
Dial gage 1 pce
Holder for dial gage 1 pce
Measuring sensor 1 pce
Clamping nut 1 pce
Fixing piece 1 pce
Alignment fork 1 pce
Operating instructions 1 pce
V10
Shock absorber assembly tool kit for passenger car and LCVDamage to the shock absorber and vehicle can be avoided by using the correct tool to install and remove shock absorbers.
Specially designed for SACHS shock absorbers, the shock
absorber installation set is a high-quality tool. It can be used
to make sure that shock absorbers with piston rod pins can
be installed correctly and without causing damage to the
piston rod.
Supplemented by two expanding socket wrench inserts,
suspension struts with clamp seats in the wheel mount
can be removed easily.
The shock absorber assembly tool kit conforms with the
requirements of the OE manufacturer and is used in line
with the OE repair guide.
Included in the package Quantity | unit
4200 080 537 21 mm passage ratchet 1 pce
½“ adapter with button for 21 mm passage ratchet 1 pce
6 mm socket wrench insert for hexagon socket 1 pce
7 mm socket wrench insert for hexagon socket 1 pce
8 mm socket wrench insert for hexagon socket 1 pce
16 mm passage socket wrench insert SW 1 pce
17 mm passage socket wrench insert SW 1 pce
18 mm passage socket wrench insert SW 1 pce
19 mm passage socket wrench insert SW 1 pce
20 mm passage socket wrench insert SW 1 pce
21 mm passage socket wrench insert SW 1 pce
22 mm passage socket wrench insert SW 1 pce
24 mm passage socket wrench insert SW 1 pce
5 x 8 socket wrench insert 1 pce
6 x 8 socket wrench insert 1 pce
5 mm expanding socket wrench insert 1 pce
5.5 mm expanding socket wrench insert 1 pce
Plastic carry case 1 pce
Cleaning system for electric contact surfacesOxidation and corrosion increase contact resistance on electric contact surfaces. Contact surfaces can be professionally cleaned with the cleaning system.
After cleaning, the contact resistance is reduced and the
full electric current is once again available to the electric
components (e.g. the starter).
V11
Included in the package Quantity | unit
4200 080 590 Battery contact cleaner with protective cover 1 pce
¼“ through-ratchet with rotary handle 1 pce
Flexible ¼“ extension 2 pce
¼“ adapter (short) for 22 x 8 mm hook-and-loop pad 1 pce
¼“ adapter (short) for 15 x 6 mm hook-and-loop pad 1 pce
¼“ adapter (short) for 15 x 8 mm hook-and-loop pad 1 pce
¼“ adapter (short) for 22 x 8 mm hook-and-loop pad 1 pce
¼“ adapter (long) for 15 x 6 mm hook-and-loop pad 1 pce
¼“ adapter (long) for 15 x 8 mm hook-and-loop pad 1 pce
Hook-and-loop pad 15 x 6 mm 50 pcs
Hook-and-loop pad 15 x 8 mm 50 pcs
Hook-and-loop pad 22 x 8 mm 50 pcs
Web ring (red), 22 x 8 mm 150 pcs
Web ring (gray), 15 x 8 mm 150 pcs
Web ring (gray), 15 x 6 mm 150 pcs
Web ring (red), 15 x 6 mm 150 pcs
Web ring (gray), 22 x 8 mm 150 pcs
Web ring (red), 15 x 8 mm 150 pcs
Operating instructions 1 pce
Plastic carry case 1 pce
1281
7 EN
ZF Friedrichshafen AG ZF AftermarketObere Weiden 12 97424 SchweinfurtGermany Fon: +49 9721 4756-0Fax: +49 9721 4755000
Technical Disclaimer: www.zf.com/[email protected]
1286
3 EN
ZF Friedrichshafen AG ZF AftermarketObere Weiden 12 97424 SchweinfurtGermany Phon: +49 9721 4756-0
[email protected] Disclaimer: www.zf.com/dis