Input Clutch "B"

Replacing input clutch "B"

Remove and install the control unit. Shift Control Unit
Replace oil pump housing. Replacing Oil Pump Housing





Configuration of input clutch "B"





Remove piston and brake band:
Bolt special tool 24 1 230 and push the cover downward slightly.





Remove circlip.





Remove special tool 24 1 230.
Remove the pistons.
1. Spacer disc (large)
2. Spacer disc (small)
3. Springs
4. Piston
5. Cover
6. Circlip





Lift out the brake band.





Remove the complete unit for clutch "A", "B" with 2nd gear freewheel and clutch "E" from input shaft.





Note: Pay attention to the thrust bearing beneath the unit on the intermediate shaft.





Lift freewheel off clutch "B".

Note: The clutch and freewheel are sticking to each other only due to the oil film.

Make sure that the freewheel does not fall apart.





Lift off clutch "B".





Note: Note configuration of thrust bearing on "A" clutch.





For installation, assemble the complete drive unit and install.
While doing so, rotate drive unit backwards and forwards until all discs engage with one another.
When correctly fitted, cylinder "B" must locate in the pot recesses in such a way that only a gap of A = approx. 1 mm is visible.





Insert new brake band:

Note: If the old brake band is reused, fit it the same way round again (do not reverse the direction).





Reinstall oil pump housing.





Measure and adjust clearance for brake band:
Install piston and available spacer discs with springs but without O-rings.
Remove special tool 24 1 230 again.





Measure and note distance between cover and sealing surface (dimension 1).





Mount special tool 24 1 240.





Unscrew knurled screw from top until the dowel pin abuts against the longitudinal slot without counter pressure.





Carefully unscrew the pressure piece until it abuts firmly.
(Use thin paper strips as feeler gage).
When doing so, push pressure piece upwards. Lock in position with a knurled nut.
Remove special tool 24 1 240.





Remove the pistons.
Remove springs and reinstall piston using the same spacer discs.
Mount special tool 24 1 240 again.





Screw upper knurled screw firmly home.
(This exerts a force of precisely 50 N on the piston).





Measure and note distance between cover and sealing surface (dimension 2).
The difference between the two dimensions measured is the clearance.

Example:
dimension 2 = 7.2 mm
-dimension 1 = 5.4 mm ____________________________
Clearance calculated = 1.8 mm
Clearance, nominal = 1.35 - 1.70 mm





If fan clearance is outside tolerance:
Remove the pistons.
Measure the thicknesses of the spacer discs.
Example:
Spacer disc (1) = 3.25 mm
Spacer disc (2) = 3.25 mm
If the clearance is too great, a corresponding thickness of spacer disc (1) and a thinner spacer disc (2) must be installed, and vice versa.
The total thickness always remains constant.

Pairs of discs:
Spacer disc (1) Spacer disc (2)
1.50 mm 5.00 mm
1.75 mm 4.75 mm
2.00 mm 4.50 mm
2.25 mm 4.25 mm
2.50 mm 4.00 mm
2.75 mm 3.75 mm
3.00 mm 3.50 mm
3.25 mm 3.25 mm
3.50 mm 3.00 mm
3.75 mm 2.75 mm
4.00 mm 2.50 mm
4.25 mm 2.25 mm

In the above example, the following spacer discs must be fitted:
Spacer disc (1) = 3.50 mm
Spacer disc (2) = 3.00 mm





Note: Lift out cover with rubber sucker or by blowing compressed air through the bore illustrated.





Fit the O-rings to the piston (4) and cover (5) and grease them.
Install the piston with springs and the thickness of spacer disc calculated.

Caution: O-rings differ in size.