problem described is worn brushes on the clutch actuator motor, had the same issue, had replaced wheel speed sensor and the clutch :no joy
checking prices for potential fix from main stealers offered repair prices ranging from 700- 2500 and couldnt guarantee the result.
Decided to attempt myself: after a lot of investigation stripping down control unit and all actuator motors (three in total) 1)clutch actuator 2) gear selector 3)gear position control
all seemed relatively good
comparing each of the bosch motor against each other with the motor housing removed and checking fo play between the brushes and rotor revealed a slight gap.
clutch control motor is the lowest mounted motor of the three
removal :
undo torx bolts located on the mounting bracket and disconnect the clutch fluid pipe and electrical connections
remove the clutch motor
undo torx bolts on the motor housing and pull housing away from motor (can feel sticky to remove due to magnetism and top bearing seating)
two plastic brush retainer protrude upward (unfortunately these need to be snapped of at the base as a circular plate is riveted into place) keep these as they will be needed later
carefully bend back two copper prongs of the internal brush sleeve and extract the brush
note (the brushes are connected via a coil configuration to the electrical supply) dont attempt to remove the coil
snip the wire close to the brush
measure the brushes as new brushes will have be of the same dimension
for brushes of the size required can be bought for only a few euro
new brushes: if a contact plate is attached to the new brushes snip this off close to the contact plate
solder the wire on the new brush to the wire protruding from the coil on the motor (ensuring spring is in position around the wire
insert into the sleeve)
bend copper prongs back into position to hold spring
replace the plastic tabs snapped off earlier by positioning in place and plastic welding them at the base using a soldering iron ( the integrity of strength of the plastic weld is not an issue so long as the plastic tab are held firmly in place until the motor housing is replaced)
refit torx screws to housing
and refit motor car
jobs a goodun
Posted Mar 1, 2014 (10 years ago)