MERCEDES-BENZ SPRINTER 2005 Service Repair Manual

(14) Remove the transmission oil filter and o-ring
from the electrohydraulic control unit.
(15) Clean the inside of the oil pan of any debris.
Inspect the oil pan gasket and replace if necessary.
(16) Install a new oil filter and o-ring into the elec-
trohydraulic control unit.
(17) Install the oil pan and gasket onto the trans-
mission.
(18) Install the oil pan bolts and retainers. Torque
the bolts to 8 N´m (70 in.lbs.).
(19) Lower the vehicle and add 7.0 L (7.4 qts.) of
transmission fluid to the transmission.
(20) Check the oil level (Refer to 21 - TRANSMIS-
SION/AUTOMATIC - NAG1/FLUID AND FILTER -
STANDARD PROCEDURE).
FREEWHEELING CLUTCH
DESCRIPTION
Freewheeling clutches (Fig. 141) are installed in
the front planetary gear set between the sun gear
and the stator shaft, and in the rear planetary gear
set between the sun gear and the intermediate shaft.The freewheel consists of an outer race (4), an
inner race (7), a number of locking elements (3) and
a cage (6) for these locking elements.
OPERATION
The freewheeling clutch (Fig. 142) optimizes indi-
vidual gearshifts. They lock individual elements of a
planetary gear set together or against the transmis-
sion housing in one direction of rotation to allow the
torque to be transmitted.
If the inner race (7) of the freewheeling clutch is
locked and the outer race (4) turns in direction9A9
(1), the locking elements (3) adopt a diagonal position
on account of their special contours, allowing the
freewheel function. The outer race (4) slides over the
locking elements (3) with negligible friction. If the
rotation of the outer race (4) changes to direction9B9
(2), the locking elements (3) stand up and lock the
outer and inner races (4, 7) together.
Fig. 141 Freewheeling Clutch
1 - ROTATION DIRECTION9A9
2 - ROTATION DIRECTION9B9
3 - LOCKING ELEMENTS
4 - OUTER RACE
5 - FRONT OR REAR SUN GEAR
6 - LOCKING ELEMENT CAGE
7 - INNER RACE
Fig. 142 Freewheeling Clutch
1 - ROTATION DIRECTION9A9
2 - ROTATION DIRECTION9B9
3 - LOCKING ELEMENTS
4 - OUTER RACE
5 - FRONT OR REAR SUN GEAR
6 - LOCKING ELEMENT CAGE
7 - INNER RACE
VAAUTOMATIC TRANSMISSION - NAG1 21 - 105
FLUID AND FILTER (Continued)

DISASSEMBLY
(1) Remove retaining ring (5) (Fig. 143) from hol-
low shaft (1).
(2) Remove rear sun gear (4) with the K3 inter-
nally toothed disk carrier and rear freewheeling
clutch F2 (3).(3) Remove snap-ring (2) (Fig. 143) for freewheel.
(4) Press freewheeling clutch out of sun gear.
(5) Check O-rings (6), replace if necessary.
(6) Check the anti-friction bearing (Fig. 144) in the
rear planetary sun gear for damage. Replace as nec-
essary.
Fig. 143 Freewheeling Clutch F2
1 - HOLLOW SHAFT 4 - K3 INNER DISC CARRIER AND REAR PLANETARY SUN GEAR
2 - SNAP-RING 5 - RETAINING RING
3 - FREEWHEELING CLUTCH F2 6 - O-RINGS
21 - 106 AUTOMATIC TRANSMISSION - NAG1VA
FREEWHEELING CLUTCH (Continued)

ASSEMBLY
(1) Press freewheeling clutch F2 (3) (Fig. 145) into
sun gear (4).
(2) Install snap-ring (2) for freewheeling clutch.
(3) Check O-rings (6) (Fig. 145) 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) Install retaining ring (5) onto hollow shaft (1).
Fig. 144 Freewheeling Clutch F2 Anti-Friction
Bearing
1 - K3 INNER DISC CARRIER AND REAR PLANETARY SUN
GEAR
2 - ANTI-FRICTION BEARING
3 - FREEWHEELING CLUTCH F2
VAAUTOMATIC TRANSMISSION - NAG1 21 - 107
FREEWHEELING CLUTCH (Continued)

Fig. 145 Freewheeling Clutch F2
1 - HOLLOW SHAFT 4 - K3 INNER DISC CARRIER AND REAR PLANETARY SUN GEAR
2 - SNAP-RING 5 - RETAINING RING
3 - FREEWHEELING CLUTCH F2 6 - O-RINGS
21 - 108 AUTOMATIC TRANSMISSION - NAG1VA
FREEWHEELING CLUTCH (Continued)

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.
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 position9D9.
(2) Remove top (3) (Fig. 146) of the center section
of instrument panel.
(3) Remove bottom (2) (Fig. 147) 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 at transmission.
(a) Unlatch ball socket latch (Fig. 148) 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).
(c) Pull shift cable out of ball socket. Ball socket
can remain on transmission lever.
(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 (Fig. 149) to the trans-
mission.
Fig. 146 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. 147 Remove Bottom Section Of Center
Instrument Panel
1 - SCREW
2 - BOTTOM CENTER PART OF INSTRUMENT PANEL
VAAUTOMATIC TRANSMISSION - NAG1 21 - 109

(a) Push shift cable onto the transmission shift
lever 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. 150) of the
center section of instrument panel.
(6) Install the top section (3) (Fig. 151) of the cen-
ter section of instrument panel.
(7) Verify repair.
Fig. 148 Remove Shift Cable From Transmission
1 - SHIFT CABLE
2 - TRANSMISSION SHIFT LEVER
Fig. 149 Install Shift Cable Onto Transmission
1 - SHIFT CABLE
2 - TRANSMISSION SHIFT LEVER
Fig. 150 Install Bottom Section Of Center
Instrument Panel
1 - SCREW
2 - BOTTOM CENTER PART OF INSTRUMENT PANEL
Fig. 151 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 - 110 AUTOMATIC TRANSMISSION - NAG1VA
GEARSHIFT CABLE (Continued)

HOLDING CLUTCHES
DESCRIPTION
Three multiple-disc holding clutches (Fig. 152), the
front, middle and rear multiple disc clutches B1, B3
and B2, 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. 152 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 21 - 111

OPERATION
The holding clutches (Fig. 153) 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) andthe annulus gear (10) are locked. When the multiple-
disc brake B3 (4) is actuated, the direction of rotation
is reversed.
HOLDING CLUTCH B1
DISASSEMBLY
(1) Remove snap-ring (7) (Fig. 154).
(2) Remove multiple-disc pack (6) and disc spring
(5) from outer multiple-disc carrier.
(3) Place the Multi-use Spring Compressor 8900
(8) (Fig. 154) on disc spring (3) and compress the
spring until the snap-ring (4) is exposed.
(4) Remove snap-ring (4).
(5) Remove piston (2) from the outer multiple-disc
carrier by carefully blowing compressed air into the
bore (A).
Fig. 153 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 - 112 AUTOMATIC TRANSMISSION - NAG1VA
HOLDING CLUTCHES (Continued)

ASSEMBLY
(1) Install piston (2) (Fig. 155) in outer multiple-
disc carrier (1). Press in piston using the disc spring
(3) and Multi-use Spring Compressor 8900 (8). Place
compressor (8) on disc spring (3) and compress until
the groove of the snap-ring is exposed
NOTE: Check vulcanized gasket, replace if neces-
sary.
(2) Insert snap-ring (4) (Fig. 155).
NOTE: The collar of the snap-ring must point
towards the multiple-disc pack. After installing,
check snap-ring for correct seat.
(3) Insert disc spring (5) and multiple-disc pack (6)
in the outer multiple-disc carrier.
(4) Insert snap-ring (7).NOTE: Pay attention to sequence of discs. Place
new friction multiple-discs in ATF fluid for one hour
before installing.
(5) Measure B1 clutch clearance.
(a) Mount Pressing Tool 8901 (1) (Fig. 156) on
outer multiple disc.
(b) Using a lever press (Fig. 156), compress
pressing tool as far as the stop (then the marking
ring is still visible, see small arrow).
(c) Using a feeler gauge, determine the play9L9
(Fig. 157) at three points between the snap-ring (6)
and outer multiple-disc (4). During the measure-
ment, the snap-ring (6) must contact the upper
bearing surface of the groove in the outer multiple-
disc carrier (5). The correct clearance is 2.3-2.7 mm
(0.091-0.106 in.) for 2 friction disc versions, 2.7-3.1
mm (0.106-0.122 in.) for 3 disc versions, and
3.0-3.4 mm (0.118-0.134 in.) for 4 disc versions.
Fig. 154 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
VAAUTOMATIC TRANSMISSION - NAG1 21 - 113
HOLDING CLUTCH B1 (Continued)

(d) 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. 155 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. 156 Measure B1 Clutch Clearance
1 - PRESSING TOOL 8901
2 - B1 CLUTCH OUTER CARRIER
21 - 114 AUTOMATIC TRANSMISSION - NAG1VA
HOLDING CLUTCH B1 (Continued)