Special tools

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 Content

Content

Part no. Page

1 LuK special tools 4

1.1 SAC mounting tool 400 0237 10 4

1.1.1 Clutch centring pin (23mm) 400 0046 10 5

1.1.2 Clutch centring pin (26.5mm) 400 0110 10 5

1.1.3 Clutch centring pin (28mm) 400 0045 10 5

1.1.4 Clutch centring pin (32.5mm) 400 0078 10 6

1.1.5 Clutch centring sleeve 400 0076 10 6

1.2 DMF special tools 400 0080 10 7

1.3 Double clutch special tool 400 0240 10 8

1.4 2CT supplementary kit 400 0420 10 9

1.5 2CT basic tool kit 400 0418 10 10

1.6 2CT Volkswagen tool kit 400 0419 10 11

1.7 2CT Renault tool kit 400 0423 10 12

1.8 2CT reset tool 400 0425 10 13

1.9 Overview of 2CT tool kit applications 14

2 INA special tools 15

2.1 OAP/OAD tool kit 400 0338 10 15

2.1.1 Alternator wrench socket set 400 0200 10 16

2.1.2 Alternator wrench socket set 400 0231 10 16

2.1.3 Alternator wrench socket set 400 0233 10 16

2.1.4 Alternator wrench socket set 400 0234 10 17

2.1.5 Alternator wrench socket set 400 0235 10 17

3 FAG special tools 18

3.1 FAG special tool for for light commercial vehicles 400 6199 10 18

4 Ruville special tools 19

4.1 PSA rear axle tool kit 1002226 19

4.2 Torsion bar tool kit 1002240 20

3
1 LuK special tools
1.1 SAC mounting tool

Part no. 400 0237 10

Supplementary information:
Content:
• 6 different tapered bushings to spread • 4 special centring pins (BMW) of Brochure:
both white tensioning/centring ele- varying diameter and corresponding Self-adjusting clutch (SAC)
ments (15-28 mm) to support the clutch screw Order no.: 999 6002 490
disc • Face spanner/releasing tool for pre-
• Universal centring pin with guide and tensioned clutches (Audi, Seat, Skoda Service Info:
tensioning element and VW) Product replacement SAC tool kit
• 3 screw-on centring pins of varying 400 0072 10 to 400 0237 10 with
diameter (12 mm, 14 mm, and 15 mm) Application: additional content, LuK 0016
for pilot bearing Using a special tool is an absolute must
• Pressure piece and spindle carrier with to ensure correct installation of the Self- Video:
3- and 4-hole pitch Adjusting Clutch. No counteracting forces LuK self-adjusting clutch (SAC)
• Centring sleeve (BMW) must be applied during installation to installation video
• 4 studs M6, M7 and M8 prevent early rotation of the adjusting
• 4 knurled nuts ring in the clutch pressure plate.
• Thread closing cover to protect the
inner thread
• 2 tensioning/centring elements (
12-28 mm) to fit pilot bearing and
crankshaft bore

4
1.1.1 Clutch centring pin 23mm
Part no. 400 0046 10
Supplementary information:
Content:
Brochure:
Clutch centring pin
Self-adjusting clutch (SAC)
Order no.: 999 6002 490
Application:
Clutch centring pin Ø 23mm for BMW
models equipped with pretensioned SAC
clutch pressure plate.

1.1.2 Clutch centring pin 26.5mm

Part no. 400 0110 10
Supplementary information:
Content:
Brochure:
Clutch centring pin
Self-adjusting clutch (SAC)
Order no.: 999 6002 490
Application:
Clutch centring pin Ø 26.5mm for BMW/
Audi models equipped with pretensioned
SAC clutch pressure plate.

1.1.3 Clutch centring pin 28mm

Part no. 400 0045 10
Supplementary information:
Content:
Brochure:
Clutch centring pin
Self-adjusting clutch (SAC)
Order no.: 999 6002 490
Application:
Clutch centring pin Ø 28mm for BMW
models equipped with pretensioned SAC
clutch pressure plate.

5
1.1.4 Clutch centring pin 32.5mm
Part no. 400 0078 10
Supplementary information:
Content:
Brochure:
Clutch centring pin
Self-adjusting clutch (SAC)
Order no.: 999 6002 490
Application:
Clutch centring pin Ø 32.5mm for BMW
models equipped with pretensioned SAC
clutch pressure plate.

1.1.5 Clutch centring sleeve

Part no. 400 0076 10
Supplementary information:

Content:
Brochure:
Centring sleeve with screw
Self-adjusting clutch (SAC)
Order no.: 999 6002 490
Application:
For centring the clutch disc on BMW
applications where the pilot bearing is
mounted in the primary shaft, e.g. on mo-
dels equipped with N54 or N55 engines.

6
1.2 DMF special tool

Part no. 400 0080 10

Application: Supplementary information:
Content: The LuK DMF special tool allows you to
• DTI stand perform the most important measure- Brochure:
• Slotted bar ments – freeplay and rock – in a garage Dual mass flywheel technical brochure
• 4 ring gear locking dog spacers environment. Order no.: 999 6002 310
• 6 adapters
• Degree gauge locking bar
• DTI gauge
• Degree gauge
• 2 ring gear locking dogs
• Instruction DVD

7
1.3 Dry double clutch special tool

Part no. 400 0240 10

Supplementary information:

Content: Application:
Special tool for professional removal Brochure:
• Setting gauge for micrometer
and installation of the dry double clutch LuK repair solution for dry double
• 3 hooks
on the first-generation 7-speed 0AM clutches, 7-speed 0AM transmission
• 3 thrust pieces
transmission installed in Audi, Skoda, on Audi, Seat, Skoda and Volkswa-
• Circlip pliers, angled
Seat and VW models (manufactured until gen models*
• 5 plugs
05.2011). Order no.: 999 6002 690
• DTI gauge with stand
• Magnet
Note: Video:
• 2 pulling hooks
This special tool has been superseded by Removal/assembly of the double
• DVD with removal/assembly instruc-
modular tool kits 400 0418 10 (basic) and clutch in a 7-speed 0AM transmissi-
tions and training video
400 0419 10 (VW). The supplementary on on Audi, Seat, Skoda and Volks-
• Cross beam with spindle and thrust
tool kit 400 0420 10 makes it compatible wagen models*
piece
• 3 knurled-head screws with the new modular tool kit system.
DVD:
• 3 threaded bolts M10, 101mm long
LuK RepSet 2CT, 7-Speed Transmis-
• 3 threaded bolts M10, 161mm long
sion 0AM in Audi, Seat, Skoda and
• Support bushing for removal
Volkswagen*
• Pressure sleeve for assembly
Order no.: 999 6003 500 Brochure,
• Micrometer 32.92mm
video, 7 languages
• Micrometer 48.63mm
• Weight 3.5kg

* Note: The brochure, film and DVD have been updated to

reflect the new modular tool kit system.
8
1.4 2CT Supplementary tool kit

Part no. 400 0420 10

Supplementary information:
Content: Application:
• Transmission support with height The previous LuK double clutch spe- Brochures:
adjustment cial tool (part no. 400 0240 10) can be LuK repair solution for dry double clut-
• 2 plugs for differential openings adapted to the new, modular tool system ches, Audi, Seat, Skoda, Volkswagen,
• Special open-end wrench range with the supplementary tool kit 7-speed 0AM transmission
• Setting dimension 32.12 mm (part no. 400 0420 10). Order no.: 999 6002 690
(2nd generation, K2) The combined content of both tool kits is
• Setting dimension 48.42 mm identical to the contents of the basic and LuK repair solution for dry double clut-
(2nd generation, K1) Volkswagen tool kits. ches, Renault 6-speed DC4 transmission
• DMF reset tool Order no.: 999 6006 310
• Unlocking key
• DVD with assembly/disassembly Video:
instructions and training video Double clutch removal/assembly on
Audi, Seat, Skoda, Volkswagen 2nd
generation 7-speed 0AM transmission

Double clutch removal/assembly on

Supplementary information: Renault 6-speed DC4 transmission

Brochures: DVD:
The dry double clutch, technology/ LuK RepSet 2CT
special tools Order no.: 999 6006 090
Order no.: 999 6006 360 Brochures, videos, 2 languages

9
1.5 2CT Basic tool kit

Part no. 400 0418 10

Supplementary information:
Content:
This is based on all dry double clutch systems Brochure:
• Puller with spindle and pressure piece
currently available from LuK. LuK repair solution for dry double
• 3 thumb screws
clutches, Renault 6-speed DC4 trans-
• 3 M10 threaded bolts, 100 mm long
mission
• 3 M10 threaded bolts, 160 mm long
Order no.: 999 6006 310
• Circlip pliers, angled
• Magnet
Video:
• Transmission support with height
Double clutch removal/assembly, Audi,
adjustment
Seat, Skoda, Volkswagen, 7-speed 0AM
• 2 plugs for driveshaft holes
transmission, 1st generation
• DMF reset tool
• Unlocking key
Supplementary information: Double clutch removal/assembly, Audi,
• Special open-end wrench
Seat, Skoda, Volkswagen, 7-speed 0AM
• DVD with assembly/disassembly instruc-
Brochures: transmission, 2nd generation
tions and training video
The dry double clutch, technology/spe-
cial tools Double clutch removal/assembly on
Application:
Order no.: 999 6006 360 Renault 6-speed DC4 transmission
The basic tool kit forms the basis of the
modular tool system. It contains those tools
LuK repair solution for dry double clut- DVD:
that are generally required for all repairs to
ches, Audi, Seat, Skoda, Volkswagen, LuK RepSet 2CT,
double clutches.
7-speed 0AM transmission Order no.: 999 6006 090
Together with a vehicle-specific tool kit, they
Order no.: 999 6002 690 Brochures, videos, 2 languages
form a complete kit for professional repairs.

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1.6 2CT Volkswagen tool kit

Part no. 400 0419 10

Supplementary information:
Content: Application:
This vehicle-specific tool kit must be Brochures:
• Dial gauge with tripod
combined with the basic tool kit. It can LuK repair solution for dry double
• Reference gauge 32.92 mm
be used to disassemble, assemble and clutches, Audi, Seat, Skoda, Volks-
(1st generation, K2)
adjust both first generation dry double wagen, 7-speed 0AM transmission
• Reference gauge 48.63 mm
clutches (up to May 2011) and second Order no.: 999 6002 690
(1st generation, K1)
• Reference gauge 32.12 mm generation dry double clutches (from June
2011) in vehicles manufactured by Audi, Videos:
(2nd generation, K2)
Seat, Škoda and Volkswagen with a 0AM Double clutch removal/assembly
• Reference gauge 48.42 mm
transmission. on Audi, Seat, Skoda, Volkswagen
(2nd generation, K1)
1st generation 7-speed 0AM trans-
• 3 thrust pieces
mission
• Support sleeve for disassembly
• Pressure sleeve for assembly
Double clutch removal/assembly
• 6 plugs
on Audi, Seat, Skoda, Volkswagen
• 3 hooks
2nd generation 7-speed 0AM trans-
• Setting gauge for reference gauge
Supplementary information: mission
• 2 pulling hooks
• Weight, 3.5 kg
Brochures: DVD:
• DVD with assembly/disassembly in-
The dry double clutch, LuK RepSet 2CT,
structions and training video
technology/special tools Order no.: 999 6006 090
Order no.: 999 6006 360 Brochures, videos, 2 languages

11
1.7 2CT Renault tool kit

Part no. 400 0423 10

Supplementary information:
Content: Application:
• 3 hooks This tool kit contains all tools that are Brochures:
• Pressure sleeve for assembly required to carry out professional repairs The dry double clutch,
• Support sleeve for disassembly on a dry double clutch on a Renault vehi- technology/special tools
• Locking piece cle (DC4 6-speed transmission). It must Order no.: 999 6006 360
• DVD with assembly/disassembly be used together with the basic tool kit.
instructions and training video LuK repair solution for dry
double clutches, Renault 6-speed
DC4 transmission
Order no.: 999 6006 310

Video:
Double clutch removal/assembly
on Renault 6-speed DC4 transmis-
sion

DVD:
LuK RepSet 2CT
Order no.: 999 6006 090
Brochures, videos, 2 languages

12
1.8 2CT Reset tool kit

Part no. 400 425 10

Application: Supplementary information:
Content: New double clutches for Renault vehicles
• Base plate with spindle with a DC4 transmission and for Ford Brochures:
• Pressure nut vehicles with a DPS6 transmission are in The dry double clutch,
• Adapter principle fitted with a transport fastener. technology/special tools
• 2 fixing pins This means that no additional work is Order no.: 999 6006 360
• 2 knurled nuts necessary prior to assembly.
• K2 pressure piece, Ø 115 mm The transport fastener must be put back LuK repair solution for dry double
• K2 pressure piece, Ø 131 mm in place if the double clutch is used again clutches, Renault 6-speed DC4
• K1 pressure ring, Ø 85 mm after disassembly, e.g. because work has transmission
• K1 pressure ring, Ø 105 mm been carried out on the transmission Order no.: 999 6006 310
• K1 return ring seals. The reset tool kit (part no. 400
• K2 return ring 0425 10) must be used for this type of Video:
• 3 K1 fixing pieces work. Resetting the transport lock, Renault
• DVD with assembly/disassembly 6-speed DC4 transmission
instructions and training video
DVD:
LuK RepSet 2CT
Order no.: 999 6006 090
Brochures, videos, 2 languages

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1.9 Overview of 2CT tool kit applications
The table below shows which tool kits need to be combined if no LuK special tool is available yet.

Audi, SEAT, Škoda, VW Audi, SEAT, Škoda, VW

Application Renault
1st generation 2nd generation

Basic tool kit

X X X
Part no. 400 0418 10
Tool kit

Volkswagen tool kit

X X
Part no. 400 0419 10

Renault tool kit

X
Part no. 400 0423 10

This table illustrates how the tool systems are combined if the LuK double clutch special tool part no. 400 0240 10 is already
available.

Audi, SEAT, Škoda, VW Audi, SEAT, Škoda, VW

Application Renault
1st generation 2nd generation

Previous LuK special tool

X X X
Part no. 400 0240 10
Tool kit

Supplementary tool kit

X X
Part no. 400 0420 10

Renault tool kit

X
Part no. 400 0423 10

If a Ford or Renault double clutch already in use is reassembled, the transport fasteners must be reset using the specified tool.

Audi, SEAT, Škoda, VW Audi, SEAT, Škoda, VW

Application Renault
1st generation 2nd generation
Tool kit

Reset tool kit

X
Part no. 400 0425 10

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2 INA special tools
2.1 OAP/OAD tool kit

Part no. 400 0338 10

Supplementary information:
Content:
• 17x20 Multipoint adapter with 33 teeth, • Torx bit with multipoint adapter, 12x14, Brochure:
A/F 21mm (31 teeth, A/F 21mm) and 1/2-inch Belt drive components
• Hexagonal adapter, A/F 21/28mm socket, TX50, 75mm long Oder no.: 944 1000 240
• Torx bit with hexagonal socket TX50, • Torx bit with 1/2-inch socket, TX50 M10,
A/F 12mm, 53mm long 73mm long Service Info:
• Hexagonal bit with internal hexagonal • 8mm hexagonal bit with hexagonal OAP/OAD tool kit, INA 0111
socket A/F 10mm, 40mm long socket, A/F 13mm, 64mm long
• Multipoint bit with hexagonal socket • 10mm hexagonal bit with hexagonal
XZN M10, A/F 12mm, 53mm long socket, A/F 13mm, 64mm long
• Adapter with 3 bolts, A/F 21mm
• Hexagonal adapter, A/F 17/21mm Application:
• Multipoint bit with 1/2-inch socket, XZN For removal and installation of overrun-
M10, 73mm long ning alternator pulleys.
• Multipoint bit with multipoint adapter,
12x14 (31 teeth, A/F 21mm) and 1/2-inch
socket, XZN M10, 75mm long
• Mulitpoint bit with 1/2-inch socket, XZN
M10, 103mm long

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2.1.1 Socket wrench set for alternators*
Part no. 400 0200 10
Supplementary information:
Content:
Brochure:
Multipoint bit with adapter, (33 teeth,
Belt drive components,
A/F 21mm) and 1/2-inch socket, XZN M10,
Oder no.: 944 1000 240
125mm long

Application:
For removal and installation of overrun-
ning alternator pulleys.

* also included in OAP/OAD tool kit 400 0338 10

2.1.2 Socket wrench set for alternators*

Part no. 400 0231 10
Supplementary information:

Content:
Brochure:
Hexagonal adapter, A/F 21/28mm, mul-
Belt drive components,
tipoint bit with hexagonal socket, XZN
Oder no.: 944 1000 240
M10, A/F 12mm, 64mm long

Application:
For removal and installation of overrun-
ning alternator pulleys.

* also included in OAP/OAD tool kit 400 0338 10

2.1.3 Socket wrench set for alternators*

Part no. 400 0233 10
Supplementary information:
Content:
Brochure:
Hexagonal bit with internal hexagonal
Belt drive components,
socket, A/F 10mm, 40mm long, multi-
Oder no.: 944 1000 240
point adapter 17x20 with 33 teeth, A/F
21mm

Application:
For removal and installation of overrun-
ning alternator pulleys.

* also included in OAP/OAD tool kit 400 0338 10

16
2.1.4 Socket wrench set for alternators*
Part no. 400 0234 10
Supplementary information:
Content:
Brochure:
Multipoint bit with hexagonal socket, XZN
Belt drive components,
M10, A/F 12mm, 53mm long, multipoint
Oder no.: 944 1000 240
adapter 17x20 with 33 teeth, A/F 21mm

Application:
For removal and installation of overrun-
ning alternator pulleys.

* also included in OAP/OAD tool kit 400 0338 10

2.1.5 Socket wrench set for alternators*

Part no. 400 0235 10
Supplementary information:

Content:
Brochure:
Torx bit with hexagonal socket, TX50, A/F
Belt drive components,
12mm, 53mm long, multipoint adapter
Oder no.: 944 1000 240
17x20 with 33 teeth, A/F 21mm

Application:
For removal and installation of overrun-
ning alternator pulleys.

* also included in OAP/OAD tool kit 400 0338 10

17
3 FAG special tools
3.1 FAG special tool for Light Commercial Vehicles

Part no. 400 6199 10

Supplementary information:
Content:
• Base plate • 2 hexagon socket screws M14 x 70 Brochure:
• Pull / pressure plate with bridge • Reinforcing rail 196 mm FAG wheel bearing repair solution
(ø 96 mm bearing – Mercedes-Benz • Reinforcing rail 140 mm for light commercial vehicles
Sprinter and VW Crafter • Steering knuckle mounting bracket Order no.: 955 1000 590
• Closing plate (ø 96 mm bearing) • DVD with removal / installation
• Pull / pressure plate (ø 92 mm bearing) instructions Service Info:
without closing plate Wheel bearing repair solution for
• Closing plate (ø 92 mm bearing) Application: vans, FAG0021
• 3 knurled screws M14 x 1.5 Front wheel bearing removal/assembly on
• 2 retaining pins with O-ring Mercedes-Benz Sprinter, Vito, Viano and Video:
• Hydraulic cylinder 17t VW Crafter, with RWD. FAG wheel bearing repair solution
• Adapter 2 1/4 -14 UNS to M42 x 2 for light commercial vehicles
• Pull / pressure spindle M20 x 600 mm
• Pressure nut with pilot pin (w/o O-ring) DVD:
• 2 supporting rods 275 mm Wheel bearing repair solution for
• Supporting rod transverse bore light commercial vehicles
• Screw with cone M16 x 1.5 x 80 Order no.: 955 1000 600
• 4 washers ø 19 mm Brochure, video, 6 languages
• 3 shoulder nuts M18

18
4 Ruville special tools
4.1 PSA rear axle tool kit

Part no. 1002226

Supplementary information:
Content: Application:
• 2 long threaded spindles (part no. Tool kit for the removal and installation of Brochures:
1002221), M20x1.5x800mm rear axle journals on different PSA models Fitting instructions Citroën Berlingo
• Coupling sleeve (part no. 1002224) equipped with torsion bar rear axles. and Peugeot Partner
M20x1.5x100mm Order no.: 999 0194 310
• Short threaded spindle (part no. 1002222)
M20x1,5x400mm Tool user manual 1002226
• Thrust tube (part no. 1002216) 57x65x- Order no.: 999 0193 870
240mm
• 2 thrust pieces (part no. 1002217 & Service Info:
1002218) 50.6x56.5/65x11mm and Technical Info no. 1106
47.7x56.5/65x11mm
• 2 thrust pieces (part no. 1002220 Video:
& 1002227) 21x33/50x20mm and Axle journal repair on Citroën
21x27/50x20mm Berlingo & Peugeot Partner rear
• End piece (part no. 1002219) Supplementary information: axles, short version
21x56.5/65x20mm
• Protective tube (part no. 1002223) 25x2x- Brochures: Axle journal repair on Citroën
150mm Fitting instructions Citroen AX and Berlingo & Peugeot Partner rear
• 2 axial bearings (part no. 51204) Saxo; Peugeot 106 and 206 axles, long version
• 2 tool nuts (part no. 31305) Order no.: 999 0193 730
• Lubricant (part no. 71343) Molykote GN+

19
4.2 Torsion bar tool kit

Part no. 1002240

Supplementary information:
Content: Application:
• Impact weight (part no. 1002228) Tool kit for torsion bar removal on Renault Service Info:
• Guide bar (part no. 1002229) and PSA rear axles. Technical Info Nr.1136
• 2 locking bars (part no. 1002230 &
1002231) Film:
• 2 thrust pins (part no. 1002233 & Axle journal repair on Citroën Ber-
1002234) lingo & Peugeot Partner rear axles,
• Connector (part no. 1002232) short version
• Thrust washers incl. screws (part no.
1002237 & 1002238 & 41127) Axle journal repair on Citroën Ber-
• 2 threaded spindles (part no. 1002236) lingo & Peugeot Partner rear axles,
• 2 angle pieces (part no. 1002235) long version
• Locking wedge (part no. 1002239)
• 2 threaded spindles (part no. 1002242)

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