Part 2 - Clutches (A/B/C)

Dismantling and Assembling Automatic Transmission (A5S 560 Z)

Part 2 - Clutches (A/B/C)





Clutches (A/B/C):
- Fit special tool 24 1 270 to the input shaft and secure with pin.
- Lift out drive unit with clutches (A/B/C) using a workshop crane and place on 2 wooden blocks.




Installation:
- The impulse spring on the top clutch housing must be located in centre of bore for impulse sensor.




Installation:
- Lower drive unit with clutches (A/B/C) into transmission case with a workshop crane.
- Twist disc carrier D (1) to and fro with a screwdriver until it engages fully in discs of D brake.




- Place drive unit with clutches (A/B/C) on its head. Remove axial needle bearing (1).

Installation:
- Secure axial needle bearing (1) with Vaseline. Coat the rectangular rings (2) with Vaseline and push them into the grooves.

Caution! If the rectangular rings (2) are too high, they can be damaged during installation.




- Bend back retaining tabs with special tool 24 1 310.




Installation:
- Do not reuse bent retaining tabs for securing purposes. Using special tool 24 1 300, first bend two opposing retaining tabs, then 4 more retaining tabs at regularly spaced intervals.




- Remove sun shaft (1).




Installation;
- Tension disc carrier C upwards with special tool 24 1 290.




- Remove axial needle bearing (1).

Installation:
- Note installation position of axial needle bearing (1).
- Coat rectangular ring (2) with Vaseline




- Lift off idler shaft (1) with clutch B (2).

Installation:
- Install clutch B (2) by rotating to and fro.




- Remove B clutch (1) angled disc (2) and axial needle bearing (3) from idler shaft (4).

Installation:
- Note installation position of angled disc (2).




Installation:
- Install idler shaft (1) in A clutch (2), rotating it to do so.




- Lift out snap ring (1) from B clutch and remove complete disc pack.

Installation:
- Note installation position of snap ring ends.
- Align lined discs.




Installation:
1. Circlip
2. Outer discs
3. Lined discs




- Remove axial needle bearing (1) and angled disc (2) from cylinder C (3).




- Lift snap ring (1) out of A clutch.

Note: The axial play of the A clutch is factory set over the thickness of the snap ring (1). Mark the snap ring (1) and install at the same location.

Installation:
- Note installation position of snap ring ends.
- Align discs on A clutch.




- Remove end disc (1) from A clutch.

Note: The end disc (1) can be identified by its longer teeth.




- Remove internal disc carrier B (1).




- Remove disc carrier C (1).

Installation:
- Install disc carrier C (1), rotating it to do so.




- Remove complete disc pack from A clutch.

Installation:
1. Spring disc
2. Outer discs
3. Lined discs




- Lift snap ring (1) out of C clutch and remove complete disc pack.

Installation:
- Note installation position of snap ring ends.
- Align lined discs.




Installation:
1. Circlip
2. Spring disc
3. Outer discs
4. Lined discs
5. Top outer disc (thicker)




- Press input shaft (1) out of cylinder A + C.

Installation:
- Replace O-ring (2).
- Replace damaged rectangular rings (3).
- For ease of assembly, coat O-ring (2) and rectangular rings (3) with Vaseline.

Continued in "Part 3 - D Brake/E1/E2 and Planetary Gear Set"