MERCEDES-BENZ SPRINTER 2006 Service Manual

Handle, Universal - C-4171
Bar, Gauge - 6311
End Play Set - 8266
Adapter, Geartrain End-play - 8266-18
Dipstick - 8863B
Compressor, Multi-use Spring - 8900
Tool, Pressing - 8901
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Installer, Seal - 8902A
Tool, Staking - 9078
Remover, Bearing - 9082
Installer, Bearing - 9287
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INPUT CLUTCHES
DESCRIPTION
Three multi-plate input clutches (1, 2, 5) (Fig. 79),
the front, middle and rear multi-plate clutches K1
(1), K2 (2), and K3 (5), are located in the planetary
gear sets in the transmission housing.
A multi-plate input clutch consists of a number of
internally toothed discs (4) on an internally toothed
disc carrier and externally toothed discs (3) on an
externally toothed disc carrier.
Fig. 79 Input Clutches
1 - K1 CLUTCH 12 - CENTER PLANETARY GEARSET SUN GEAR
2 - K2 CLUTCH 13 - K2 CLUTCH EXTERNALLY TOOTHED DISC CARRIER
3 - EXTERNALLY TOOTHED DISC 14 - K2 CLUTCH PISTON
4 - INTERNALLY TOOTHED DISC 15 - FRONT PLANETARY GEARSET PLANETARY CARRIER
5 - K3 CLUTCH 16 - FRONT PLANETARY GEARSET ANNULUS GEAR
6 - K3 CLUTCH EXTERNALLY TOOTHED DISC CARRIER 17 - FRONT PLANETARY GEARSET SUN GEAR
7 - K3 CLUTCH PISTON 18 - K1 CLUTCH INTERNALLY TOOTHED DISC CARRIER
8 - K3 CLUTCH INTERNALLY TOOTHED DISC CARRIER 19 - K1 CLUTCH EXTERNALLY TOOTHED DISC CARRIER
9 - REAR PLANETARY GEARSET SUN GEAR 20 - K1 CLUTCH PISTON
10 - CENTER PLANETARY GEARSET PLANETARY CARRIER 21 - DRIVE SHAFT
11 - CENTER PLANETARY GEARSET ANNULUS GEAR
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OPERATION
The input clutches (Fig. 80) produce a non-positive
locking connection between two elements of a plane-
tary gear set or between one element from each of
two planetary gear sets in order to transmit the drive
torque.
If the piston (20) on multi-plate clutch K1 (1) is
subjected to oil pressure, it presses the internal and
external discs of the disc set together. The sun gear
(17) is locked with the planetary carrier (15) via the
externally toothed disc carrier (19) and the internally
toothed disc carrier (18). The front planetary gear set
is thus locked and turns as a closed unit.
If the multi-plate clutch K2 (2) is actuated via the
piston (14), the piston compresses the disc set. The
annulus gear (16) of the front planetary gear set is
locked with the annulus gear (11) of the center plan-
etary gear set via the externally toothed disc carrier(13) and the center planetary carrier (10) on which
the internally toothed discs are seated. Annulus gear
(16) and annulus gear (11) turn at the same speed as
the input shaft (21)
If the multi-plate clutch K3 (5) is actuated via the
piston (7), the piston compresses the disc set. The
sun gear (12) of the center planetary gear set is
locked with the sun gear (9) of the rear planetary
gear set via the externally toothed disc carrier (6)
and the internally toothed disc carrier (8). Sun gear
(12) and sun gear (9) turn at the same speed.
Fig. 80 Input Clutches
1 - K1 CLUTCH 12 - CENTER PLANETARY GEARSET SUN GEAR
2 - K2 CLUTCH 13 - K2 CLUTCH EXTERNALLY TOOTHED DISC CARRIER
3 - EXTERNALLY TOOTHED DISC 14 - K2 CLUTCH PISTON
4 - INTERNALLY TOOTHED DISC 15 - FRONT PLANETARY GEARSET PLANETARY CARRIER
5 - K3 CLUTCH 16 - FRONT PLANETARY GEARSET ANNULUS GEAR
6 - K3 CLUTCH EXTERNALLY TOOTHED DISC CARRIER 17 - FRONT PLANETARY GEARSET SUN GEAR
7 - K3 CLUTCH PISTON 18 - K1 CLUTCH INTERNALLY TOOTHED DISC CARRIER
8 - K3 CLUTCH INTERNALLY TOOTHED DISC CARRIER 19 - K1 CLUTCH EXTERNALLY TOOTHED DISC CARRIER
9 - REAR PLANETARY GEARSET SUN GEAR 20 - K1 CLUTCH PISTON
10 - CENTER PLANETARY GEARSET PLANETARY CARRIER 21 - DRIVE SHAFT
11 - CENTER PLANETARY GEARSET ANNULUS GEAR
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 91

INPUT CLUTCH K1
DISASSEMBLY
(1) Remove snap-ring (11) (Fig. 81) from outer
multiple-disc carrier (6).
(2) Take multiple-disc pack (12) out of outer mul-
tiple-disc carrier (6). Note which clutch disc is
removed just prior to the spring plate (8) for re-as-
sembly. If the clutch discs are re-used, this disc must
be returned to its original position on top of the
spring plate.
Fig. 81 Input Clutch K1 Components
1 - K1 OUTER DISC CARRIER 7 - DISC SPRING
2 - FREEWHEELING CLUTCH F1 8 - SPRING PLATE
3 - SNAP-RING 9 - SPRING PLATE SEALING RING
4 - OUTER DISC CARRIER SEALING RING 10 - SNAP-RING
5 - PISTON SEALING RING 11 - SNAP-RING
6 - PISTON 12 - MULTIPLE DISC PACK - REFER TO TEXT FOR CORRECT
ASSEMBLY ORDER
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(3) Place Multi-use Spring Compressor 8900 (2)
(Fig. 82) on the spring plate and compress the spring
until the snap-ring (1) is exposed.
(4) Remove snap-ring (1).
(5) Take out disc spring (7) and remove piston (6)
by carefully blowing compressed air into the drilled
oil feed passage.
(6) Remove snap-ring (3) and take out front free-
wheeling clutch F1 (2). Take care when removing the
F1 clutch to prevent the clutch sprags from falling
out. If this occurs, the clutch must be replaced.
Fig. 82 Compress the Disc Spring
1 - SNAP-RING
2 - MULTI-USE SPRING COMPRESSOR 8900
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 93

ASSEMBLY
(1) Install piston (6) (Fig. 83) in the outer multi-
ple-disc carrier (1). Check sealing rings (4 and 5),
replace if necessary. The rounded off edges of the
sealing rings must point outwards.
(2) Insert disc spring (7) (Fig. 83). Insert disc
spring with the curvature towards the piston.
(3) Insert spring plate (8). Insert spring plate with
the curvature towards the sun gear. Check sealing
ring (9), replace if necessary.
Fig. 83 Input Clutch K1 Components
1 - K1 OUTER DISC CARRIER 7 - DISC SPRING
2 - FREEWHEELING CLUTCH F1 8 - SPRING PLATE
3 - SNAP-RING 9 - SPRING PLATE SEALING RING
4 - OUTER DISC CARRIER SEALING RING 10 - SNAP-RING
5 - PISTON SEALING RING 11 - SNAP-RING
6 - PISTON 12 - MULTIPLE DISC PACK - REFER TO TEXT FOR CORRECT
ASSEMBLY ORDER
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(4) Place Multi-use Spring Compressor 8900 (2)
(Fig. 84) on spring plate and compress the spring
until the groove of the snap-ring (1) is exposed.
(5) Insert snap-ring (1) (Fig. 83). After installing,
check snap-ring for correct seat.
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 externallylugged 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 return
the disc identified on disassembly as belonging on
top of the spring plate (8) to its original location.
NOTE: Place new friction multiple-discs in ATF fluid
for one hour before installing.
(6) Insert multiple-disc pack (12) in the outer mul-
tiple-disc carrier.
(7) Insert snap-ring (11).
(8) Measure the K1 clutch pack clearance by
mounting Pressing Tool 8901 (1) (Fig. 85) 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) For transmissions using double sided friction
discs, use a feeler gauge to determine the play ªLº
(Fig. 86) at three points between the snap-ring (5)
and outer multiple-disc (3).
(11) During the measurement the snap-ring (5)
must contact the upper bearing surface of the groove
in the outer multiple-disc carrier (4).
(12) The correct clutch clearance for transmissions
with double sided friction discs is 2.7-3.1 mm (0.106-
0.122 in.) for three friction disc versions, 3.0-3.4 mm
Fig. 84 Compress the Disc Spring
1 - SNAP-RING
2 - MULTI-USE SPRING COMPRESSOR 8900
Fig. 85 Measure K1 Clutch Clearance
1 - PRESSING TOOL 8901
2 - K1 OUTER DISC CARRIER
Fig. 86 Input Clutch K1 Stack-up - Double Sided
Discs
1 - OUTER MULTIPLE DISC - 1.8MM (0.071 IN.)
2 - OUTER MULTIPLE DISC - 2.8MM (0.110 IN.)
3 - OUTER MULTIPLE DISC - 4.0MM (0.158 IN.)
4 - K1 OUTER DISC CARRIER
5 - SNAP-RING
6 - FRICTION DISCS
7 - DISC SPRING
8 - PISTON
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(0.118-0.134 in.) for four disc versions, 3.3-3.7 mm
(0.130-0.146 in.) for five disc versions, and 3.6-4.0
mm (0.142-0.158 in.) for six disc versions.
(13) 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.).
(14) Insert front freewheeling clutch F1 (2) and fit
snap-ring (3). The freewheeling clutch F1 (2) must be
installed in the direction of the arrow.
(15) For transmissions using single sided friction
discs, use a feeler gauge to determine the play ªLº
(Fig. 87) at three points between the snap-ring (4)
and outer multiple-disc (2).
(16) During the measurement the snap-ring (4)
must contact the upper bearing surface of the groove
in the outer multiple-disc carrier (3).
(17) The correct clutch clearance for transmissions
with single sided friction discs is 2.4-2.8 mm (0.095-
0.110 in.) for six friction disc versions, 2.6-3.0 mm
(0.102-0.118 in.) for eight disc versions, 2.8-3.2 mm
(0.110-0.126 in.) for ten disc versions, and 2.9-3.3 mm
(0.114-0.130 in.) for twelve disc versions.
(18) Adjust with snap-ring (4), 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.).
(19) Insert front freewheeling clutch F1 (2) and fit
snap-ring (3). The freewheeling clutch F1 (2) must be
installed in the direction of the arrow.
Fig. 87 Input Clutch K1 Stack-up - Single Sided
Discs
1 - OUTER MULTIPLE DISCS
2 - OUTER MULTIPLE DISC - 4.0MM (0.158 IN.)
3 - K1 OUTER DISC CARRIER
4 - SNAP-RING
5 - INNER MULTIPLE DISCS
6 - DISC SPRING
7 - PISTON
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INPUT CLUTCH K2
DISASSEMBLY
(1) Remove snap-ring (19) from the K1 inner mul-
tiple-disc carrier with integrated front gear set (2)
and take off hollow gear (18).
(2) Remove input shaft with clutch K2 (5) (Fig.
88).
(3) Remove needle thrust bearing (3).
(4) Remove snap-ring (17) (Fig. 88) from K2 outer
multiple-disc carrier.
(5) Take out multiple-disc pack (16). Note which
clutch disc is removed just prior to the disc spring
(14) 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.
(6) Take out disc spring (14) (Fig. 88).
Fig. 88 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
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