Dissembling, Assembling and Measuring Clutch K1

Disassembling, Assembling and Measuring Clutch K1

Preceding work:
Removing, installing transmission with torque converter. Remove and Installing Transmission With Torque Converter

Disassembling, transmission. Disassembling Transmission







Snap ring
Remove with a screwdriver, install.

Disc set (6, 7/8,10) and Belleville spring washer (15)
Remove complete from externally toothed disc carrier (1), install. Arrange in order according to transmission model. Place the Belleville spring washers with the curved side onto the piston. After installing, measure play "A" 0.7 - 1.2 mm and adjust (step 7).

Snap ring (5)
Remove, install by tensioning spring plate (4) with assembly device 201 589 12 43 00 until the snap ring is exposed.

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

Piston (2)
Withdraw when installing, introduce piston with insertion sleeve, outside 201 589 01 14 00. Check lip sealing rings (12 and 13), renew if necessary and install with sealing lips down the way (step 6).


Special Tools











Order of installing clutch discs

Clutch Discs:

Clutch Discs:

Clutch Discs:

Clutch Disc Versions:

Return Springs For Clutch Pistons:

Disassembly and Assembly






1. Take Out 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
Pay attention to the order of the clutch discs. Arrange disc set according to transmission model.
Place Belleville spring washer with the curved face onto the piston.






3. Fit assembly device (020) 201 589 12 43 00 onto the spring plate (4) and tension until snap ring (5) is exposed. Take out snap ring (5).

4. Relieve tension on assembly device (020) and take off.






Installation Instruction
Alter inserting snap ring, check to ensure it is properly seated.

5. Take off spring plate (4) and compression springs (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.






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

Note:
Check O-ring between externally toothed disc carrier and piston guide ring for signs of leaks To this, fill a little petroleum or cleaning naphtha info the piston guide ring, then check whether the liquid runs away.

If a leak is present, renew the externally toothed disc carrier.






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

Insert lip sealing rings (12 and 13) into the piston (2) so that the sealing lips are pointing down the way (direction of arrow).






Place insertion sleeve (022) 201 589 01 14 00 into the externally toothed disc carrier (1).

Oil insertion sleeve and also the lip sealing rings (12 and 13) with ATF oil.






Carefully insert piston (2) and press into the externally toothed disc carrier (1) without tilting it.

Take oft insertion sleeve (022).

Measuring

7. Determine the play "A" with a feeler gauge.






Note:
Effective Transmission End No. 243 517, the play "A" is set with the snap ring (11). which is available in 3 thicknesses (2.0 - 2.5 - 3.0 mm). The groove for the snap ring is thus cut 3.2 mm wide. Only if the specified play "A" is not reached with the snap ring (11), is it then necessary to additionally compensate with the middle externally toothed discs - as is the case with transmissions with a lower Transmission End No.
Adjust the play to 0.7 - 1.2 mm.