Dissembling, Assembling and Measuring Clutch K2

Disassembling, Assembling and Measuring Clutch K2

Preceding work:

Removing, installing transmission with torque Converter. Remove and Installing Transmission With Torque Converter

Disassembling transmission. Disassembling Transmission






Snap ring (11)
Remove with a screwdriver, install.

Disc set (6.7/8, 10)
Remove complete from externally toothed disc carrier (1). install, arrange in order according to transmission model (step 2). After installing, measure play "A" 0.7 - 1.3 mm and adjust (step 6).

Snap ring (5)
Remove, install by tensioning spring plate (4) with assembly device 126 589 On 43 On until the snap ring is exposed (step 3)


Spring plate (4) and compression springs (3)
Take off. pay attention to number of springs (step 4).

Piston (2)
Withdraw. Check lip sealing rings (12 and 13), renew it necessary. Install sealing lips down the way (step 5).

O-ring in externally toothed disc carrier (1)
Check for leaks with petroleum or washing naphtha; if a leak exists renew the externally toothed disc carrier.

Special Tool






Return springs for clutch pistons (The number of springs is determined by weighing, for this reason. up to 2 springs fewer may be fitted).
Transmission 722.4
Qty. 20
Wire dia. in mm 0.7
Length untensioned in mm approx. 27.5 ± 0.6

Order of clutch discs

Clutch Disc Versions:

Adjustment Data:

Disassembly and Assembly

1. Takeout snap ring (11).






Installation Instruction
After inserting snap ring, press snap ring up around its entire circumference with a screwdriver.

2. Tilt externally toothed disc carrier (1) and take out disc set. Examine internally toothed discs for signs of scorching and wear.






Installation Instruction
Place new discs approx. 1 hour in ATF oil before installing.
Pay attention to order of clutch discs. Arrange disc set according to transmission model.

3. Place assembly device (020) 201 589 12 43 00 onto the spring plate and tension until snap ring (5) is exposed. Take out snap ring.






Installation Instruction
After installing snap ring, ensure that it is correctly seated.

4. Take off spring plate (4) and compression spring (3).






Installation Instruction
Pay attention to number of return springs and ensure that each spring is centered by a guide stud of the spring plate.






5. Pull piston (2) out of the externally toothed disc carrier (1).

Note:
Examine O-ring between externally toothed disc carrier and piston guide ring for leaks by filling a little petroleum or washing naphtha into the piston guide ring. Then check whether the liquid runs away.

If a leak exists, renew the externally toothed disc carrier.






Installation Instruction
Examine sealing rings (12 and 13) for signs of wear or damage; renew, if necessary.

Insert sealing ring (12), ensuring that the sealing ring is not twisted in itself.

Insert lip sealing ring (13) into the piston (2) 50 that the lip is pointing down the way (in direction of arrow).






Oil sealing rings (12 and 13) with ATF oil.

Carefully place piston (2) into the externally toothed disc carrier. Press piston down, while turning it slightly, making sure that it is not twisted.

Measuring

6. Determine play "A" with a feeler gauge.
Set the play to 0.7 - 1.3 mm.






Note:
Effective Transmission End No.234 517 the play "A" is set with the snap ring, which is available in 3 thicknesses (2.0/2.5/3.0 mm). The groove for the snap ring is cut to 3.2 mm. If the specified play "A" is not achieved with the snap ring (11), it must be compensated additionally with the middle externally.