Procedures
Plug-in couplings for hydraulic lines - as of model year 2009
Information
Information on steering and clutch lines
The plug-in lines (plug-in couplings) for the steering and clutch hydraulics -arrows- have been changed. Introduction from model year 2009 onwards.
Plug-in coupling (steering and clutch hydraulics)
Plug-in couplings -arrows- are no longer loosened/disconnected by screwing them apart.
The lines are now pulled apart after releasing the plug connection. Use loosening tool 9780 for releasing plug connections.
Do not use any other (commercially available) loosening tools! There is a danger of damaging the plug connection (making it necessary to replace the line).
Plug-in coupling as of model year 2009
Plug-in coupling components - as of model year 2009
1 - Connector (with line)
2 - Plug-in sleeve (with line)
3 - Loosening sleeve
4 - 60° chamfer
5 - Axial spring (dirt seal and pretension element)
6 - Support ring
7 - O-ring/support ring assembly (item 7) = system seal
8 - Retaining ring (for locking)
9 - Base ring (for locking)
Plug-in couplings up to model year 2008
Loosening plug-in coupling by pulling it apart
Plug-in coupling is loosened by screwing it apart. (Remove circlip -D-/turn at the threaded joint -A- and counter at the hexagon on the plug-in coupling -B- at the same time).
Lines are joined by plugging them together.
Connecting line by plugging it in
The plug-in coupling must first be screwed together (with the retaining collar).
New plug-in couplings are already screwed together.
Plug-in couplings as of model year 2009
Plug-in coupling is loosened by releasing it and then pulling the lines apart.
Special tool 9780 is required for releasing plug-in couplings!
Releasing plug-in coupling (as of model year 2009)
Lines are joined by plugging them together.
Connecting lines by plugging them in (as of model year 2009)
The plug-in coupling on the steering lines (pressure and return line) is the same.
But the line diameter is different (as before).
Do not confuse the lines when joining them (plugging together) if possible.
Opening and closing plug-in couplings - as of model year 2009
Information
^ The new plug-in couplings (as of model year 2009) are precision components, just like the previous plug connections.
^ These precision components must be handled carefully during repairs. Excess force during assembly work, damage to the sealing surface and soiling can cause leaks.
^ Perform preparations carefully when handling plug-in couplings as repairs are possible only by replacing the affected line in most cases.
^ Only use loosening tool 9780 for opening (releasing) the plug-in couplings! If a different (commercially available) loosening tool is used, the plug-in connection can become damaged if it is not handled properly, e.g. as a result of incorrect positioning or levering.
^ Only the O-ring (item 7) and the axial spring (item 5) are available as spare parts (repair kit).
Plug-in coupling as of model year 2009
1. Open plug-in coupling using loosening tool (special tool 9780).
Releasing plug-in coupling (as of model year 2009)
1.1. Release plug-in coupling using loosening tool 9780.
To do this, fit the special tool on the loosening sleeve plate -3- and insert it as far as it will go over the 60° chamfer -(in direction of arrow)-.
If the tool is turned 180° before fitting, it cannot be inserted.
The 60° chamfer on the loosening tool must be facing the 60° chamfer from the connector (line -1-)!
1.2. Once you have released the plug-in coupling (by inserting the loosening tool), pull the lines apart -arrows-.
Disconnecting lines after releasing plug-in coupling
Collect hydraulic fluid in a container. Close off lines with suitable stoppers (e.g. from new lines) to prevent damage in the sealing area. Alternatively, cover the plug-in couplings using a clean, lint-free cloth.
1.3. Pull special tool 9780 off the line -1- (off the connector).
Special tool 9780
2. Close plug-in couplings.
2.1. Replace the O-ring -7- and axial spring -5- if necessary. Then connect the lines (plug-in coupling) -1 and 2- (-(arrow)-).
Connecting lines/available spare parts
2.2. Check that the plug-in coupling is locked correctly.
Locked plug-in coupling
Pull on the connector -1- to check that the plug-in coupling is locked (push and pull slightly in axial direction).
Counter at the plug-in sleeve -2- while doing this.
If the plug-in coupling is locked correctly, you should be able to feel slight axial play between the connector -1- and plug-in sleeve -2-. A plug-in coupling cannot be partly locked. Another sure sign of a correctly locked plug-in coupling is the bulbous shape of the axial spring -5-.