Dismantle/Assemble Drive Shaft w/ Clutch K2 & Front Gear Set
DISASSEMBLY
1. Remove transmission housing at converter housing
2. Remove multiple disc clutch K1, K2 and K3
3. Remove snap ring (84b) from the inner multiple-disc carrier/clutch K1 with integrated front gear set (84) and remove internally-geared wheel (84a)
4. Remove drive shaft with clutch K2 (100)
5. Remove needle thrust bearing (85)
6. Remove snap ring (106) from outer multiple-disc carrier clutch K2
7. Take out multiple-disc pack (105)
- Check multiple-discs for burnt spots and wear
8. Place assembly device (076) on spring plate (103) and press until the snap ring 004) is exposed (figure A)
- Operate assembly device with a lever press
9. Remove snap ring (104)
10. Take out disc spring (102) and pull piston (101) out of multiple-disc carrier
ASSEMBLY
1. Install piston (101) in outer multiple-disc carrier
- Check sealing ring (101a and 101b), replace if necessary
- The rounded off edges of the sealing rings must point outwards
2. Insert disc spring (102) and spring plate (103)
- Insert disc spring (102) with the curvature towards the spring plate (103)
- Check sealing ring (103a), replace if necessary.
3. Place assembly device (076) on spring plate (103) and press until the groove of the snap ring is exposed
4. Insert snap ring (104)
5. Insert multiple-disc pack (105) in the outer multiple-disc carrier and measure as follows:
a. Refer to survey of multiply disc components to locate correct number of discs for this application. Application and ID
b. Observe outer multiple-disc sequence of installation, then procedures as follows:
c. Place discs for multiple-disc clutch K2 together in the sequence shown in the illustration above
d. Using a feeler gauge, determine the play "L" at three points between the snap ring (106) and the outer disc (105c)
- During the measurement the snap ring (106) must contact the upper bearing surface of the groove in the disc carrier
Adjustment Values Multiple Disc Clutch K2
Number Of Discs: 3
Clearance Dimension "L": 0.70-1.70 mm
Number Of Discs: 4
Clearance Dimension "L": 0.70-1.70 mm
Number Of Discs: 5
Clearance Dimension "L": 0.70-1.80 mm
Number Of Discs: 6
Clearance Dimension "L": 0.70-1.80 mm
e. Using the table above determine the correct clearance based on the number of discs installed.
f. Adjust clearance "L" using a snap ring of the correct thickness
- Snap rings are available in thicknesses of2.30, 2.60, 2.90, 3.20 and 3.50 mm
6. Fit snap ring (106)
7. Insert needle thrust bearing (85) in inner multiple-disc carrier/K1
8. Insert needle thrust bearing (85) with some grease to prevent it slipping
9. Install drive shaft in inner multiple-disc carrier/clutch K1 with integrated front gear set
10. Fit internally-geared wheel (84a)