clutch MERCEDES-BENZ SPRINTER 2006 Owners Manual

(7) Fit Multi-use Spring Compressor 8900 (1) (Fig.
89) onto spring retainer (12) and press until snap-
ring (2) is released.
(8) Remove snap-ring (2) (Fig. 88).
(9) Take out disc spring (10) and pull piston (9) out
of outer multiple-disc carrier.
Fig. 89 Compress K2 Clutch Spring
1 - MULTI-USE SPRING COMPRESSOR 8900
2 - SNAP-RING
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ASSEMBLY
(1) Install piston (9) (Fig. 90) in outer multiple-
disc carrier. Inspect seals (6 and 7), replace if neces-
sary. The rounded edges of the inner piston seal (7)
must point to the outside.
(2) Insert disk spring (10) and spring retainer (12).
Insert disk spring (10) with curved side pointing
toward spring retainer (12). Inspect seal (11) (Fig.
90), replace if necessary.
Fig. 90 Input Clutch K2 Components
1 - NEEDLE ROLLER BEARING 11 - SPRING RETAINER SEALING - O-RING
2 - K1 INNER DISC CARRIER WITH INTEGRATED FRONT GEAR
SET12 - SPRING RETAINER
3 - THRUST BEARING 13 - SNAP-RING
4 - TORLON SEAL RINGS 14 - DISC SPRING
5 - INPUT SHAFT AND K2 CLUTCH 15 - EXTERNALLY TOOTHED PLATE - 1.8 MM (0.071 IN.)
6 - PISTON OUTER SEAL RING - O-RING 16 - MULTIPLE DISC PACK
7 - PISTON INNER SEAL RING 17 - SNAP-RING
8 - THRUST WASHER 18 - HOLLOW GEAR
9 - PISTON 19 - SNAP-RING
10 - DISC SPRING
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 99

(3) Place Multi-use Spring Compressor 8900 (1)
(Fig. 91) on spring plate and press until the groove
(2) of the snap-ring is exposed.
(4) Insert snap-ring.
(5) Insert disk spring (14).
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 (14) to its original location.
(6) Insert multiple-disk set (16) into outer multi-
ple-disk carrier.
(7) Fit snap-ring (17).(8) Measure K2 clutch clearance by mounting
Pressing Tool 8901 (1) (Fig. 92) on outer multiple
disc.
(9) Using a lever press, compress pressing tool as
far as the stop (then the marking ring is still visible,
see small arrow).
(10) Using a feeler gauge, determine the play ªLº
(Fig. 93) at three points between the snap-ring (6)
and outer multiple-disc (4).
Fig. 91 Compress K2 Clutch Spring
1 - MULTI-USE SPRING COMPRESSOR 8900
2 - SNAP-RING
Fig. 92 Measure K2 Clutch Clearance
1 - PRESSING TOOL 8901
2 - K1 INNER DISC CARRIER
Fig. 93 Input Clutch K2 Stack-up
1 - DISC SPRING
2 - OUTER MULTIPLE DISC - 1.8 MM (0.071 IN.)
3 - OUTER MULTIPLE DISC - 3.5 MM (0.138 IN.)
4 - OUTER MULTIPLE DISC - 4.0 MM (0.158 IN.)
5 - K2 OUTER DISC CARRIER
6 - SNAP-RING
7 - FRICTION DISCS
8 - PISTON
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(11) During the measurement the snap-ring (6)
must contact the upper bearing surface of the groove
in the outer multiple-disc carrier.
(12) The correct clutch clearance is 2.3-2.7 mm
(0.091-0.106 in.) for three friction disc versions, 2.4-
2.8 mm (0.095-0.110 in.) for four disc versions, 2.5-2.9
mm (0.099-0.114 in.) for five disc versions, and 2.7-
3.1 mm (0.106-0.122 in.) for six disc versions.
(13) Adjust with snap-ring (6), if necessary. Snap-
rings are available in thicknesses of 2.3 mm (0.091
in.), 2.6 mm (0.102 in.), 2.9 mm (0.114 in.), 3.2 mm
(0.126 in.), 3.5 mm (0.138 in.), and 3.8 mm (0.150
in.).
(14) Insert axial needle bearing (3) into K1 inner
multiple-disk carrier. Insert axial needle bearing (3)
with a little grease to prevent it slipping.
(15) Install input shaft in K1 inner multiple-disc
carrier with integrated front gear set (2).
(16) Fit internally-geared wheel (18) and install
snap-ring (19). Pay attention to installation position.
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 101

INPUT CLUTCH K3
DISASSEMBLY
(1) Remove snap-ring (1) (Fig. 94) from outer mul-
tiple-disc carrier.
(2) Remove multiple-disc pack (2) and disk spring
(3) from outer multiple-disc carrier. Note which
clutch disc is removed just prior to the spring plate
(3) for re-assembly. If the clutch discs are re-used,
this disc must be returned to its original position on
top of the spring plate.
(3) Place Multi-use Spring Compressor 8900 (9)
(Fig. 94) on disc spring (5) and compress the spring
until the snap-ring (4) is exposed.
(4) Remove snap-ring (4).
(5) Remove spring plate (5) and piston (6) from
outer multiple-disc carrier.
Fig. 94 Input Clutch K3 Components
1 - SNAP-RING 6 - PISTON
2 - MULTIPLE DISC PACK 7 - SEALING RING
3 - DISC SPRING 8 - OUTER DISC CARRIER
4 - SNAP-RING 9 - MULTI-USE SPRING COMPRESSOR 8900
5 - SPRING PLATE
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ASSEMBLY
(1) Install piston (6) (Fig. 95) in the outer multi-
ple-disc carrier (8). Check sealing ring (7), replace if
necessary. The rounded off edges of the sealing ring
must point outwards.
(2) Insert disc spring (5). Insert disc spring with
the curvature towards the piston.
(3) Mount the Multi-use Spring Compressor 8900
(9) on the spring plate and clamp until the snap-ring
groove is exposed.
(4) Insert snap-ring (4). The collar of the snap-ring
must point towards the multiple-disc pack.
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: Pay attention to the sequence of discs. If the
original clutch discs are reused, be sure to returnthe disc identified on disassembly as belonging on
top of the spring plate (3) to its original location.
NOTE: Place new friction multiple-discs in ATF fluid
for one hour before installing.
(5) Install disk spring (3) and multiple-disc pack
(2) in outer multiple-disc carrier (8).
(6) Insert snap-ring (1).
Fig. 95 Input Clutch K3 Components
1 - SNAP-RING 6 - PISTON
2 - MULTIPLE DISC PACK 7 - SEALING RING
3 - DISC SPRING 8 - OUTER DISC CARRIER
4 - SNAP-RING 9 - MULTI-USE SPRING COMPRESSOR 8900
5 - SPRING PLATE
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 103

(7) Measure the K3 clutch clearance by mounting
Pressing Tool 8901 (1) (Fig. 96) on outer multiple
disc.
(8) Using a lever press, compress pressing tool as
far as the stop (then the marking ring is still visible,
see small arrow).
(9) For transmissions using double sided friction
discs, use a feeler gauge to determine the play ªLº(Fig. 97) at three points between the snap-ring (8)
and outer multiple-disc (2).
(10) During the measurement the snap-ring (8)
must contact the upper bearing surface of the groove
in the outer multiple-disc carrier.
(11) The correct clutch clearance for transmissions
with double sided friction discs is 2.3-2.7 mm (0.091-
0.106 in.) for three friction disc versions, 2.4-2.8 mm
(0.095-0.110 in.) for four disc versions, and 2.5-2.9
mm (0.099-0.114 in.) for five disc versions.
(12) Adjust with snap-ring (8), if necessary. Snap-
rings are available in thicknesses of 2.0 mm (0.079
in.), 2.3 mm (0.091 in.), 2.6 mm (0.102 in.), 2.9 mm
(0.114 in.), 3.2 mm (0.126 in.), and 3.5 mm (0.138
in.).
(13) For transmissions using single sided friction
discs, use a feeler gauge to determine the play ªLº
(Fig. 98) at three points between the snap-ring (7)
and outer multiple-disc (2).
(14) During the measurement the snap-ring (7)
must contact the upper bearing surface of the groove
in the outer multiple-disc carrier.
(15) The correct clutch clearance for transmissions
with single sided friction discs is 2.3-2.7 mm (0.091-
0.106 in.) for six friction disc versions, 2.4-2.8 mm
(0.095-0.110 in.) for eight disc versions, and 2.5-2.9
mm (0.099-0.114 in.) for ten disc versions.
(16) Adjust with snap-ring (7), if necessary. Snap-
rings are available in thicknesses of 2.0 mm (0.079
in.), 2.3 mm (0.091 in.), 2.6 mm (0.102 in.), 2.9 mm
Fig. 96 Measure K3 Clutch Clearance
1 - PRESSING TOOL 8901
2 - OUTER DISC CARRIER
Fig. 97 Input Clutch K3 Stack-up - Double Sided
Discs
1 - OUTER DISC CARRIER
2 - OUTER MULTIPLE DISC - 4.0 MM (0.158 IN.)
3 - OUTER MULTIPLE DISC - 2.8 MM (0.110 IN.)
4 - OUTER MULTIPLE DISC - 1.8 MM (0.079 IN.)
5 - DISC SPRING
6 - PISTON
7 - FRICTION DISCS - 2.1 MM (0.083 IN.)
8 - SNAP-RING
Fig. 98 Input Clutch K3 Stack-up - Single Sided
Discs
1 - OUTER DISC CARRIER
2 - OUTER MULTIPLE DISC - 4.0 MM (0.158 IN.)
3 - OUTER MULTIPLE DISCS
4 - DISC SPRING
5 - PISTON
6 - INNER MULTIPLE DISCS
7 - SNAP-RING
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Torque Converter Lockup Clutch Regulating Valve
The torque converter lock-up clutch regulating
valve (6) (Fig. 102) is located in the valve housing of
the electrohydraulic control module. The valve is
responsible for the hydraulic control of the torque
converter lockup clutch and distribution of the lubri-
cating oil.
Fig. 102 Torque Converter Lockup Clutch Regulating Valve
1 - TORQUE CONVERTER LOCK-UP CLUTCH
2 - TORQUE CONVERTER OUTPUT
3 - TORQUE CONVERTER INPUT
4 - LUBRICATION
5 - TORQUE CONVERTER LOCK-UP SOLENOID6 - TORQUE CONVERTER LOCK-UP CLUTCH REGULATING
VA LV E
7 - OIL COOLER
8 - LINE PRESSURE REGULATING VALVE
9 - OIL PUMP
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 107

Command Valve
Each shift group possesses one command valve (3)
(Fig. 104). The 1-2 / 4-5 and 2-3 command valves are
installed in the shift valve housing, the 3-4 command
valve is installed in the valve housing. The command
valve switches the shift group from the stationary
phase to the shift phase and back again.
Fig. 104 Command Valve
1 - HOLDING CLUTCH B1
2 - DRIVING CLUTCH K13 - 1-2/4-5 COMMAND VALVE
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 109

Shift Pressure Shift Valve
Each shift group possesses one shift pressure shift
valve (4) (Fig. 106). The 1-2 / 4-5 and 2-3 shift pres-
sure shift valves are installed in the shift valve hous-
ing; the 3-4 shift pressure shift valve is installed in
the valve housing. It assigns the shift pressure (p-S)
to the activating actuator and the overlap pressure
(p-š) regulated by the overlap regulating valve to the
deactivating actuator.
Lubrication Pressure Regulating Valve
The lubrication pressure regulating valve (1) (Fig.
107) is located in the valve housing of the electrohy-
draulic control module. The valve controls the fluid
to lubricate and cool the mechanical part of thetransmission, and limits the pressure in the torque
converter.
Shift Pressure Regulating Valve
The shift pressure regulating valve (1) (Fig. 108) is
located in the valve housing of the shift plate. It reg-
ulates the shift pressure (p-S).
Fig. 106 Shift Pressure Shift Valve
1 - 1-2/4-5 COMMAND VALVE
2 - DRIVING CLUTCH K13 - HOLDING CLUTCH B1
4 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE
Fig. 107 Lubrication Pressure Regulating Valve
1 - LUBRICATION PRESSURE REGULATING VALVE
Fig. 108 Shift Pressure Regulating Valve
1 - SHIFT PRESSURE REGULATING VALVE
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 111