MERCEDES-BENZ SPRINTER 2006 Service Manual

ASSEMBLY
NOTE: The side of the freewheeling clutch F2 (3)
with the markings (directional arrow, part number,
etc.) must be up when the clutch is installed in the
sun gear (4).
(1) Press freewheeling clutch F2 (3) (Fig. 158) into
sun gear (4).
(2) Install snap-ring (2) for freewheeling clutch.
(3) Check O-rings (6) (Fig. 158) on hollow shaft,
replace if necessary.
(4) Install rear sun gear (4) with K3 internally
toothed disc carrier and rear freewheeling clutch (3)
onto the hollow shaft.
(5) Verify proper operation of the freewheeling
clutch F2. When the assembly is held with the F2clutch snap-ring upward, it should be possible to
rotate the hollow shaft counter-clockwise.
(6) Install retaining ring (5) onto hollow shaft (1).
GEARSHIFT CABLE
DIAGNOSIS AND TESTING
GEARSHIFT CABLE
(1) The floor shifter lever and gate positions
should be in alignment with all transmission PARK,
NEUTRAL, and gear detent positions.
(2) Engine starts must be possible with floor shift
lever in PARK or NEUTRAL gate positions only.
Fig. 158 Freewheeling Clutch F2
1 - HOLLOW SHAFT 4 - K3 INNER DISC CARRIER AND REAR PLANETARY SUN
GEAR
2 - F2 CLUTCH SNAP-RING 5 - RETAINING RING
3 - FREEWHEELING CLUTCH F2 6 - O-RINGS
21 - 138 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

Engine starts must not be possible in any other gear
position.
(3) With floor shift lever handle push-button not
depressed and lever in:
(a) PARK position - Apply forward force on cen-
ter of handle and remove pressure. Engine starts
must be possible.
(b) PARK position - Apply rearward force on cen-
ter of handle and remove pressure. Engine starts
must be possible.
(c) NEUTRAL position - Normal position. Engine
starts must be possible.
(d) NEUTRAL position - Engine running and
brakes applied, apply forward force on center of
shift handle. Transmission shall not be able to shift
from NEUTRAL to REVERSE.
REMOVAL
(1) Move selector lever to position ªDº.
(2) Remove top (3) (Fig. 159) of the center section
of instrument panel.(3) Remove bottom (2) (Fig. 160) of the center sec-
tion of instrument panel.
(4) Pry ball socket of transmission shift cable off
ball knob at the shift lever assembly (SLA). Use a
suitable slotted screwdriver.
(5) Raise and support vehicle.
(6) Detach shift cable (1) at transmission.
(a) Unlatch ball socket latch (Fig. 161) of cable.
(b) Unclip shift cable retainer from retainer
bracket. When pulling out cable, press together
hooks of shift cable retainer at the points shown
(arrows).
Fig. 159 Remove Top Section Of Center Instrument
Panel
1 - SHIFT LEVER ASSEMBLY FRAME TRIM
2 - STORAGE COMPARTMENT
3 - TOP CENTER PART OF INSTRUMENT PANEL
4 - SCREW
5 - PLUG CONNECTIONS
6 - ASHTRAY
Fig. 160 Remove Bottom Section Of Center
Instrument Panel
1 - SCREW
2 - BOTTOM CENTER PART OF INSTRUMENT PANEL
Fig. 161 Remove Shift Cable From Transmission
1 - SHIFT CABLE
2 - TRANSMISSION SHIFT LEVER
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 139

(c) Pull shift cable out of ball socket. Ball socket
can remain on transmission lever (2).
(7) Remove the shift cable grommet from the dash
panel.
(8) Remove the shift cable from the vehicle.
INSTALLATION
(1) Pass the shift cable through the opening in the
dash panel and seat the shift cable grommet into the
hole.
(2) Install the shift cable (1) (Fig. 162) to the
transmission.
(a) Push shift cable onto the transmission shift
lever (2) ball socket.
(b) Latch ball socket latch of cable.
(c) Clip shift cable retainer into retainer bracket.
(3) Lower vehicle.
(4) Install the transmission shift cable onto the
ball knob at the SLA.
(5) Install the bottom section (2) (Fig. 163) of the
center section of instrument panel.
(6) Install the top section (3) (Fig. 164) of the cen-
ter section of instrument panel.
(7) Verify repair.
Fig. 162 Install Shift Cable Onto Transmission
1 - SHIFT CABLE
2 - TRANSMISSION SHIFT LEVER
Fig. 163 Install Bottom Section Of Center
Instrument Panel
1 - SCREW
2 - BOTTOM CENTER PART OF INSTRUMENT PANEL
Fig. 164 Install Top Section Of Center Instrument
Panel
1 - SHIFT LEVER ASSEMBLY FRAME TRIM
2 - STORAGE COMPARTMENT
3 - TOP CENTER PART OF INSTRUMENT PANEL
4 - SCREW
5 - PLUG CONNECTIONS
6 - ASHTRAY
21 - 140 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

HOLDING CLUTCHES
DESCRIPTION
Three (Fig. 165) multiple-disc holding clutches, the
front, B1 (1), middle, B3 (4), and rear multiple disc
clutches, B2 (5), are located in the planetary gear
sets in the transmission housing.
A multiple-disc holding clutch consists of a number
of internally toothed discs (10) on an internally
toothed disc carrier and externally toothed discs (9)
on an externally toothed disc carrier, which is rigidly
connected to the transmission housing.
Fig. 165 Holding Clutches
1 - B1 CLUTCH 10 - CENTER PLANETARY GEARSET ANNULUS GEAR
2 - EXTERNALLY TOOTHED DISC 11 - CENTER PLANETARY GEARSET PINION GEARS
3 - INTERNALLY TOOTHED DISC 12 - CENTER PLANETARY GEARSET SUN GEAR
4 - B3 CLUTCH 13 - FRONT PLANETARY GEARSET PINION GEARS
5 - B2 CLUTCH 14 - FRONT PLANETARY GEARSET SUN GEAR
6 - B3 CLUTCH PISTON 15 - B1 CLUTCH INTERNALLY TOOTHED DISC CARRIER
7 - B2 CLUTCH PISTON 16 - B1 CLUTCH PISTON
8 - B2 CLUTCH INTERNALLY TOOTHED DISC CARRIER 17 - B1 CLUTCH EXTERNALLY TOOTHED DISC CARRIER
9 - REAR PLANETARY GEARSET PLANETARY CARRIER
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 141

OPERATION
The holding clutches (Fig. 166) connect the annu-
lus gear, sun gear, or planetary carrier of a planetary
gear set against the transmission housing in order to
transmit the drive torque.
If the piston (16) on multiple-disc holding clutch
B1 (1) is subjected to oil pressure, it presses the
internal (3) and external discs (2) of the disc set
together. The internally toothed disc carrier (15)
locks the sun gear (14) against the housing. The
planetary pinion gears (13) turn on the sun gear (14).
If the multiple-disc holding clutch B2 (5) is actu-
ated via the piston (7), the piston compresses the disc
set. The internally toothed disc carrier (8) locks the
sun gear (12) against the housing. The planetary pin-
ion gears (11) turn on the sun gear (12).
If the multiple-disc holding clutch B3 (4) is actu-
ated via the piston (6), the planetary carrier (9) and
the annulus gear (10) are locked. When the multiple-disc brake B3 (4) is actuated, the direction of rotation
is reversed.
Fig. 166 Holding Clutches
1 - B1 CLUTCH 10 - CENTER PLANETARY GEARSET ANNULUS GEAR
2 - EXTERNALLY TOOTHED DISC 11 - CENTER PLANETARY GEARSET PINION GEARS
3 - INTERNALLY TOOTHED DISC 12 - CENTER PLANETARY GEARSET SUN GEAR
4 - B3 CLUTCH 13 - FRONT PLANETARY GEARSET PINION GEARS
5 - B2 CLUTCH 14 - FRONT PLANETARY GEARSET SUN GEAR
6 - B3 CLUTCH PISTON 15 - B1 CLUTCH INTERNALLY TOOTHED DISC CARRIER
7 - B2 CLUTCH PISTON 16 - B1 CLUTCH PISTON
8 - B2 CLUTCH INTERNALLY TOOTHED DISC CARRIER 17 - B1 CLUTCH EXTERNALLY TOOTHED DISC CARRIER
9 - REAR PLANETARY GEARSET PLANETARY CARRIER
21 - 142 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

HOLDING CLUTCH B1
DISASSEMBLY
(1) Remove the teflon rings (1) (Fig. 167) from the
B1 plate carrier hub (2).
Fig. 167 Remove the Teflon Rings
1 - TEFLON RINGS
2 - PLATE CARRIER HUB
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 143

(2) Remove snap-ring (7) (Fig. 168).
(3) Remove multiple-disc pack (6) and disc spring
(5) from outer multiple-disc carrier. Note which
clutch disc is removed just prior to the disc spring (5)
for re-assembly. If the clutch discs are re-used, this
disc must be returned to its original position on top
of the disc spring.
(4) Place the Multi-use Spring Compressor 8900
(8) (Fig. 168) on disc spring (3) and compress the
spring until the snap-ring (4) is exposed.
(5) Remove snap-ring (4).
(6) Remove piston (2) from the outer multiple-disc
carrier by carefully blowing compressed air into the
bore (A).
Fig. 168 Holding Clutch B1
1 - HOLDING CLUTCH B1 OUTER CARRIER 5 - DISC SPRING
2 - PISTON 6 - MULTIPLE DISC PACK
3 - DISC SPRING 7 - SNAP-RING
4 - SNAP-RING 8 - MULTI-USE SPRING COMPRESSOR 8900
21 - 144 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

ASSEMBLY
NOTE: Check vulcanized gasket, replace if neces-
sary.
(1) Install piston (2) (Fig. 169) in outer multiple-
disc carrier (1).
(2) Place compressor (8) on disc spring (3) and
compress until the groove of the snap-ring is exposed.
NOTE: The collar of the snap-ring must point
towards the multiple-disc pack. After installing,
check snap-ring for correct seat.
(3) Insert snap-ring (4) (Fig. 169).
(4) Insert disc spring (2) (Fig. 170) in the outer
multiple-disc carrier. Observe the disc spring (2)
installation position. The lugs of the disc spring (2)
Fig. 169 Holding Clutch B1
1 - HOLDING CLUTCH B1 OUTER CARRIER 5 - DISC SPRING
2 - PISTON 6 - MULTIPLE DISC PACK
3 - DISC SPRING 7 - SNAP-RING
4 - SNAP-RING 8 - MULTI-USE SPRING COMPRESSOR 8900
Fig. 170 Install the Disc Spring
1 - B1 MULTIPLE-DISC CARRIER
2 - DISC SPRING
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 145

washer must align with the 3 raised pads (arrow) of
the B1 multiple-disc carrier (1). The cone of the
spring washer must point downwards.
(5) Insert the multiple-disc pack (6) in the outer
multiple-disc carrier and measure the clutch clear-
ance.
NOTE: Pay attention to the sequence of discs. If the
original clutch discs are reused, be sure to return
the disc identified on disassembly as belonging on
top of the disc spring (5) to its original location.
CAUTION: When working with double sided friction
discs, an externally lugged steel plate is installed
first, followed by a friction disc, and continuing on
until all the required discs are installed. When work-
ing with single sided friction discs, an externally
lugged disc is installed first, followed by an inter-
nally lugged disc, and continuing on until all the
required discs are installed. All single sided discs
are installed with the friction side up.
NOTE: Place new friction multiple-discs in ATF fluid
for one hour before installing.
(6) Measure B1 clutch clearance by mounting
Pressing Tool 8901 (1) (Fig. 171) on outer multiple
disc.
(7) Using a lever press (Fig. 171), compress press-
ing tool as far as the stop (then the marking ring is
still visible, see small arrow).(8) For transmissions using double sided friction
discs, use a feeler gauge to determine the play ªLº
(Fig. 172) at three points between the snap-ring (6)
and outer multiple-disc (4). During the measurement,
the snap-ring (6) must contact the upper bearing sur-
face of the groove in the outer multiple-disc carrier
(5). The correct clearance for transmissions using
double sided friction discs is 2.3-2.7 mm (0.091-0.106
in.) for two friction disc versions, 2.7-3.1 mm (0.106-
0.122 in.) for three disc versions, and 3.0-3.4 mm
(0.118-0.134 in.) for four disc versions.
(9) Adjust with snap-ring (6), if necessary. Snap-
rings are available in thicknesses of 2.6 mm (0.102
in.), 2.9 mm (0.114 in.), 3.2 mm (0.126 in.), 3.5 mm
(0.138 in.), 3.8 mm (0.150 in.), and 4.1 mm (0.162
in.).
Fig. 171 Measure B1 Clutch Clearance
1 - PRESSING TOOL 8901
2 - B1 CLUTCH OUTER CARRIER
Fig. 172 B1 Clutch Stack-up - Double Sided Discs
1 - DISC SPRING
2 - OUTER MULTIPLE DISC - 1.8 mm (0.071 IN.)
3 - OUTER MULTIPLE DISC - 2.8 mm (0.110 IN.)
4 - OUTER MULTIPLE DISC - 4.0 mm (0.158 IN.)
5 - B1 OUTER CARRIER
6 - SNAP-RING
7 - INNER MULTIPLE DISCS
8 - PISTON
21 - 146 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

(10) For transmissions using single sided friction
discs, use a feeler gauge to determine the play ªLº
(Fig. 173) at three points between the snap-ring (5)
and outer multiple-disc (3). During the measurement,
the snap-ring (5) must contact the upper bearing sur-
face of the groove in the outer multiple-disc carrier
(4). The correct clearance is 2.2-2.6 mm (0.087-0.102
in.) for four friction disc versions, 2.4-2.8 mm (0.095-
0.110 in.) for six disc versions, and 2.6-3.0 mm
(0.102-0.118 in.) for eight disc versions.
(11) Adjust with snap-ring (5), if necessary. Snap-
rings are available in thicknesses of 2.6 mm (0.102
in.), 2.9 mm (0.114 in.), 3.2 mm (0.126 in.), 3.5 mm
(0.138 in.), 3.8 mm (0.150 in.), and 4.1 mm (0.162
in.).(12) Install the teflon rings (1) (Fig. 174) onto the
B1 plate carrier hub (2).
(13) Coat Teflon rings (1) lightly with grease and
insert in the groove so that the joint remains
together.
Fig. 173 B1 Clutch Stack-up - Single Sided Discs
1 - DISC SPRING
2 - OUTER MULTIPLE DISC
3 - OUTER MULTIPLE DISC - 4.0 mm (0.158 IN.)
4 - B1 OUTER CARRIER
5 - SNAP-RING
6 - INNER MULTIPLE DISCS
7 - PISTON
Fig. 174 Install the Teflon Rings
1 - TEFLON RINGS
2 - PLATE CARRIER HUB
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 147