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

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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

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ZF Friedrichshafen AG ZF AftermarketObere Weiden 12 97424 SchweinfurtGermany Fon: +49 9721 4756-0Fax: +49 9721 4755000

Technical Disclaimer: www.zf.com/disinfo.zf-aftermarket@zf.comwww.zf.com

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3 EN

ZF Friedrichshafen AG ZF AftermarketObere Weiden 12 97424 SchweinfurtGermany Phon: +49 9721 4756-0

info.zf-aftermarket@zf.comaftermarket.zf.comTechnical Disclaimer: www.zf.com/dis