Smart 451 Clutch Actuator DIY Service

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Here we examine how to #remove , #service , and #reinstall a #clutch #actuator on a #smart #fortwo #451 with the 1.0L Mitsubishi engine. IT is very common for the clutch actuator to have difficulty engaging and disengaging, over time, the insides of the actuator dry out and lubrication fails, requiring excessive power to move the clutch. A common symptom of a failing actuator is when the #headlights get #dim while the clutch is shifting, as well as the #3barsofdeath and also if the car won't engage a #gear when coming out of neutral. Common #OBD #codes when this occurs are #P0805 Clutch Position Sensor Circuit, #P0700 Transmission Control System Malfunction,
#P0701 Transmission Control System Range/Performance, #P0702 Transmission Control System Electrical, #P0780 Shift Malfunction, #P0810 Clutch position control error, #P0901 Clutch actuator -circuit range/performance.
0:00 Intro
1:03 Actuator Removal
2:52 Disassembly and Cleaning
9:17 Software Coding Adaptation

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Опубликовано:

3 авг 2024

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Комментарии : 88

@christopherl.miller4092 9 месяцев назад

Thanks so much for making these videos. This particular one was perfect for what I needed to do. It actually gave me the courage to do it on my own. The most I have ever done before is change the air filters and the spark plugs lol. The job went without a hitch, and the car pulls away from a stop and shifts through the gears much more smoothly now.

@PBGarage 9 месяцев назад

Glad it was helpful! Stay tuned for more to come.

@victoradorno6047 10 месяцев назад

Yo estoy pensando en comprarme uno,pero veo vídeos para familiarizarme con la mecánica de este auto que me gusta mucho. Aprendo mucho con tus vídeos ,gracias por tomar tiempo para hacerlos . Saludos desde la isla de Puerto Rico .

@christopherl.miller4092 9 месяцев назад

Este vídeo me ayudó mucho. Me dio el valor para hacer este trabajo. Funcionó mucho mejor después de hacerlo. Saludos desde Nueva Jersey, los estados unidos.

@PBGarage 9 месяцев назад

Thanks for watching! We really appreciate it, hope that all the info helped you pick a good one to buy!

@PBGarage 9 месяцев назад

Glad our video was helpful to get the job done!

@raymondmcdonald7085 Год назад

Thanks for the info. When I was looking for a smart to buy, one that I test drove had shifting issues. At the time I didn't know what was wrong but I knew something wasn't right. The owner tried to convince me the shifting was normal. I passed on the purchase of that one and purchased another that shifted normal. I have worked on most everything I have ever owned and I must say these smarts are engineered a little different. Good to know!

@PBGarage Год назад

Yeah they take some getting used to but once you have the right tools and a bit of practice they aren’t so bad. Always have to remember it’s a whole car worth of stuff rammed into a half a car so it’s bound to be challenging lol

@geidsonqueiroz2680 Год назад

hello friend I have a smart 451 mhd I have a clutch problem. I can't start the car it won't start I have a total of 04 DTC faults. can you help me thanks in advance

@jixxen Год назад

Thank you for the video! Our smart is often not shifting into reverse or drive; I’ll try this fix over the weekend.

@PBGarage Год назад

Worth a try for sure!

@jixxen Год назад

@@PBGarage Well, still having intermittent problems shifting into reverse, but at least I know my actuator is good and greased now!

@ribbitism Год назад

@@jixxen smart did recognise this problem and put out an ecu update because some of these wouldn't push with enough force to get it into reverse, the update made it have just a little bit more force to engage. try moving the car forward a little by foot or with first gear and then try reverse (basically to reposition the gear so it slides in easier). if you find this regularly works, you probably need the updated software. you might have to pay for it now, if it never got it when they were offering.

@bquattrog Год назад

Good video. Those mounting bolts didn't look like they wanted to go!

@PBGarage Год назад

No they didn’t! Really made me work for it to not snap them or round the heads.

@Smartsparky 6 месяцев назад

Can’t believe I’m about to tackle this myself. Wish me luck!

@PBGarage 6 месяцев назад

Mark the position!

@anthonymoore8480 10 месяцев назад

Great info!!! 🙌 😇

@PBGarage 9 месяцев назад

Thanks for watching! Glad to help!

@MathieuTechMoto Год назад

Thank you !

@PBGarage Год назад

Happy to help!

@lordzevallos Год назад

Do you need the teach in program if you’re just greasing/cleaning the clutch actuator or only if you replace it ?

@PBGarage Год назад

If you mark it really well when you remove it, and you reinstall it in exactly the same spot you don’t need the tool necessarily.

@yamahar1sho Год назад

Your video has been very helpful on this, my only question is how exactly did you get the actuator fully retracted? I tried plugging the connectors together and turning the key into the on position (didn’t start the ignition), tried switching gears and nothing happened. Using the paddles when shifting to the second gear, there was a clicking sound, but still no movement. The way it is extended right now, it isn’t possible to bolt it back to the vehicle. Any help on this would be greatly appreciated!!

@PBGarage Год назад

I’ve been able to get it to retract by just turning the key on and off with the actuator plugged in. If it won’t retract it could be an issue with the actuator. If you have STAR/DAS you can also force the actuator to the open or close position from within the software, but again it might not work if the actuator is totally dead.

@yamahar1sho Год назад

@@PBGarage We have tried turning the key on and off, maybe it’s toast. Thanks for your quick response on this.

@bertlzansinger 11 месяцев назад

Many thanks for this informative video. I miss, in which position the car was set (N, R, 1) prior the exchange and if the battery was disconnected prior removal, though. Any hints on that? [I do not have a tool for relearning the clutch or delete error codes] Cheers

@PBGarage 11 месяцев назад

Hello. In North America the cars have P, but for rest of world you’ll want to leave it in N and disconnect the battery.

@bertlzansinger 11 месяцев назад

cheers mate! @@PBGarage

@lesprudence374 Год назад

Hi just a question why remove from car if plastic cover just comes off with just 6 screws which can be done in situation never made sense to me? Or am I missing something. Love video's keep them coming. Thanks

@PBGarage Год назад

Glad the vids are helpful! I haven’t tried to remove the cover in place, but I think it would be really tough to do with it installed on the car since the heads of those 6 screws face up towards the engine/trans, so getting access would be very difficult compared to the relatively small effort of removing the 3 bolts and one electrical connector. It’s good to tackle those bolts at your leisure when the car is running properly so that when the actuator does fail, they come out easily as well and you’re not breaking them late on a Sunday night in a blizzard when you have to get to work the next morning.

@danyalhussain9525 5 месяцев назад

Hi I wanted to replace with a brand new on will I have to reprogram or can it just work plug and play if it is in the correct position

@PBGarage 5 месяцев назад

It might be difficult to get it to activate properly if replacing with a new one. You can adjust it somewhat by hand. If the clutch engages too harshly move the actuator closer to the flywheel and if it slips or doesn’t engage move it away from the flywheel. But it can be very difficult to adjust it properly that way if you aren’t experienced mechanically as it must be adjusted in very small increments and you must be very confident in your ability to feel how it is engaging.

@danyalhussain9525 5 месяцев назад

@@PBGarage never mind I’ll leave it at the garage this seems a bit complicated, my car just stalls completely when in gear and got told it’s a simple fix of replacing the actuator but it sounds a bit complicated. Thanks for the response

@minitrucker68 9 месяцев назад

Found the issue with my coolant leak on my Fortwo but I have no idea what this part is called that I’m looking at.. it’s the assembly that was next to the thermostat.. has an in and out and a small fitting off the side that goes to a hard line and connects close to the thermo sensor.. well that fitting is broke clean off and someone before me used about a tube of silicone to stop the leak long enough for me to find it lol

@PBGarage 9 месяцев назад

That’s a bummer that they sold it to you broken. Do you mean the flat plastic housing that bolts to the head? With the one big pipe and the one little pipe?

@minitrucker68 9 месяцев назад

Hey yeah now that I have the motor down “in service mode” I see a lot of questionable things.. there’s probably a tube of orange RTV on miscellaneous things here and there. That being said I found the part I was looking for. The water outlet pipe. And it’s the small fitting that was broke completely off and they Jimmy rigged it enough to pass safety. While the engine is down I may as well swap out the reluctor rings for the abs as I had an abs light come on on the way home from picking it up from the shady dealership downtown in Ottawa 😒

@elwynrowlands9486 11 месяцев назад

Does anyone know if it’s ok to take an old actuator off and replace it with a new actuator in the same position as the old one without the software / re-teach stages? Will it be ok simply by fitting the new actuator in the same location as the old one? I have sockets and spanners but no software / clever technology.

@PBGarage 11 месяцев назад

It’s tough to know for sure. But you can shimmy the actuator in/out to get it dialed depending on how it’s driving. It takes some fiddling but I’ve done it without the software.

@gplusgplus2286 11 месяцев назад

Is it really necessary to do the adaptation? I just bought a new clutch, mine is done and will service the actuator but I don't have the software. Service manual says to install the actuator 3 lines in from the point it barely touches.

@PBGarage 10 месяцев назад

I’ve managed to do it just by feel or trial and error driving the car. But it’s tricky.

@AdrianA4M Год назад

I wonder if one couldn't use a 'trans oil' instead of grease? Measure the volume inside and then add maybe 50% of the volume in oil? Your thoughts guys?

@PBGarage Год назад

The problem with any kind of trans oil is that I think it will melt/soften the rubber boot or the various gears/seals etc in the actuator. If you had a silicon based lube of some kind that was non reactive maybe? Not sure.

@neftaliortiz8877 Год назад

Hi I just put the new clutch actuator on my smart car,,connect and everything and the car not run is like in parking all the time not neutral or nothing when I change gears the actuator not move or nothing what the solution after a brand new clutch actuator?

@PBGarage 11 месяцев назад

First thing to do would be to check your wiring to see that it hasn’t rubbed against the transmission and worn through

@JimothyPP Год назад

I've got a nice "crunch" noise almost every time I shift into reverse. I'm hoping doing this will solve my issue... However I don't have access to the DAS system so I'm hoping the car can sort of "re-learn" itself.

@PBGarage Год назад

Just make very sure that you mark the position of the actuator before you take it off and make sure you put it back on in the same spot and you should be fine.

@elwynrowlands9486 11 месяцев назад

What if you take an old actuator off and replace it with a new actuator in the same position as the old one? Will that also be ok without the software / re-teach stages?@@PBGarage

@Windtee 6 месяцев назад

@@elwynrowlands9486 I replaced my old actuator with a new Sachs made in Germany and positioned it in the exact spot the old one was in. No relearning software used.

@jeffsmystic Год назад

Which grease did you use?

@PBGarage Год назад

Bel Ray waterproof grease.

@rapunzeleh546 3 месяца назад

okay, should have watched this before... took the thing out, mine has rivets so can't take it apart and grease it. so slip the boot off and grease inside. put it back in, now it make a banging noise. didn't know it had to be relearned.... obviously i don'[t have smart software to do that, anyways around that?

@PBGarage 3 месяца назад

If you have it reinstalled in the same position as when you took it out you should be ok. Even if you were way off it still shouldn’t make a banging noise. Sounds like the clutch release fork may be worn through or you have some other issue with the clutch pack. You could try moving the position of the actuator forward or back and try again to see if you can get close to a proper alignment, if the clutch engages too harshly move the actuator towards the flywheel. If the clutch slips too much and the car doesn’t move, slide the actuator away from the flywheel. You may have bigger issues.

@rapunzeleh546 3 месяца назад

@@PBGarage well before i 'touched it' there weren't any noises. could i have reversed the connector? i know 1 and 6 are the power in... i don't have a wiring diagram to see what colours coming in should correspond to those. so two things i'll try once this rain stops. loosen the screws and lets it go were it needs to go. (thinking about it, wondering if it pivotted - i did check the position of the first screw, the one that is easiest to get. but the one behind i didn't... will also try to flip the connector.

@PBGarage 3 месяца назад

@rapunzeleh546 the connector should only go one way.

@rapunzeleh546 3 месяца назад

@@PBGarage the plastic was really brittle and the tabs broke off... can it still only go in one way?

@PBGarage 3 месяца назад

@rapunzeleh546 no idea

@BB.......... Год назад

Where do you find that software?

@PBGarage Год назад

I bought the multiplexer and software on AliExpress. Just search MB Star you should get some hits. Mine is a C3 but I think there’s other options available now.

@MiloFarms 8 месяцев назад

@@PBGarage Do you have a link or any more information on what MB Star program and equipment I would need for a 2015 Smart?

@Windtee 7 месяцев назад

I did the rebuild and experienced marginal actuator improvement, but not enough to stop the hard slamming into reverse. Was curious to see what my local MB Smart service would find. They hoped to find $2,400.00 in my wallet... in order to replace the unit as a starting point for diagnosis. In other words, they weren't completely positive if the actuator was faulty. Crazy! Unfortunately, I still had to pay for the expensive diagnostic walk-around by the "smart technician." I'm considering buying a new OEM Sachs and installing myself. Out of curiosity, could the clutch-actuator's electric motor be a contributing issue to the slamming?

@PBGarage 7 месяцев назад

The actuator clean and lube here helps a ton in most cases, when you had it in did they re-teach the clutch engagement point? I do think there comes a point where the issue starts to be in the clutch pack itself and no longer with the actuator.

@Windtee 7 месяцев назад

@@PBGarage I don't know if Mercedes-Benz attempted a re-teach, but here is a direct quote from my recent service-receipt given to me yesterday when I picked up my smart. "Customer states they took apart the clutch actuator and now there is a hard shift to reverse followed by a clunking noise, shifter is hard to go into park and jerks going into drive. CDCE perform diagnostic scan, retrieving engine fault codes related to the CEL. Road test to verify complaint. Preliminary evaluation provides technician path to cause of failure." "Multiple codes indicating clutch actuator fault, performed actuation test of clutch motor via SDS and actuator repeatedly failed test. Visible damage to boot at actuator, will require starting with replacement of clutch actuator. Customer declined repairs." "Check Engine light is on." I hope it's not the clutch-assembly. Been there, done that on a 1983 Mazda years ago. BTW, subscribed. Thanks for your vids.

@user-xf2fo1cs1q 7 месяцев назад

I had a similar issue and it turn out to be broken clutch pressure plate. Save yourself the trouble and the expense, replace the clutch yourself. This all seems to affect 451 models from 2012 onward the SACH pressure plate were manufactured in China.@@Windtee

@PBGarage 7 месяцев назад

It’s definitely seeming like the “3 bars of death” failures are most often related to the clutch actuator, whereas if the actuator is in good condition, adjusted, and the car’s still shifting poorly, then it’s more often an issue with the actual clutch pack.

@Windtee 6 месяцев назад

@@PBGarage @user-xf2fo1cs1q I bought a new Sachs actuator and will install this week. I'll get back with updates after testing.

@jeffsmystic Год назад

Where can I get a new actuator?

@PBGarage Год назад

Mercedes/smart dealer network. There are also online sources.

@leewilhelm6700 8 месяцев назад

What kind of grease did you use?

@PBGarage 8 месяцев назад

I used Bel Ray Waterproof Grease. But any dielectric or silicone based grease will work well. I didn’t want to use anything that could attack the plastics like regular wheel bearing grease or the like.

@MrMr123 9 месяцев назад

That car has 216,000 MILES on it.... wtf.... wow

@PBGarage 9 месяцев назад

216k km, not miles, if I said miles in the video that’s a mistake lol. That being said I’ve seen plenty of 451s over 200k miles, they’ll do the mileage if they’re looked after.

@cftpm678 Месяц назад

En français s’il vous plaît, 👀🧐🇨🇦

@PBGarage Месяц назад

S’agit d’ouvrir la caisse de l’actuateur, nettoyer, lubrifier avec un produit à base de silicone, et réinstaller sur les mêmes marques. C’est à dire, sans changer la position de l’actuateur relatif à la transmission. Si possible, utiliser le programme STAR par Mercedes pour effectuer une adaptation numérique.

@cftpm678 Месяц назад

@@PBGarage , merci 🇨🇦

@petarpiljak9552 7 месяцев назад

You couldn't solve the clutch problem this way. It would be great if the problems were solved with a little lubrication. Your clutch is worn out and the actuator does not have enough power to push it to the end position. You cannot do the learning procedure if the actuator does not disengage the clutch completely.

@PBGarage 7 месяцев назад

You’re talking about 2 different issues. Clutch actuator binding is common and easily solved with cleaning/lubrication. When the actuator hits a limit on current flow it will cause the 3 bars of death and/or poor shifting. I’ve brought many many 450s and 451s back from the dead with just this service. Beyond that, there are other issues with the clutch that we are going to look at in future videos but this is the best first stop towards resolving clutch/gearbox issues.

@Ritarvt 6 месяцев назад

My 2009 (146,000 miles) started misbehaving late November. It would stall and be very jumpy at times. I never got the 3 bars or any other engine lights. But I did get a code for the clutch actuator. Upon finding your video for how to take it off, clean and lubricate it, I just finished this! Slightly delayed because I had knee surgery! But I was able to do this service as you instructed (marked the bolts, etc) and test drove today! It shifted extremely smooth! I’m hoping that this lasts another many miles as I love this car!! And as for as the other ladies who don’t think they can do it, you can!! Thank you for this great tutorial!!

@PBGarage 6 месяцев назад

@Ritarvt I’m so glad to hear it! It’s an easy DIY as long as everything gets marked off and put back the same way. Glad to hear your car feels way better!

@Ritarvt 6 месяцев назад

I am very grateful for your video! Made things super easy!