Mercedes-Benz Sprinter / Dodge Sprinter. Service manual — part 440
(12) Install oil pump (6) and securely tighten.
Tighten the oil pump bolts to 20 N·m (177 in.lbs.).
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AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION
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(13) Using grease, insert sealing rings (7) (Fig. 53)
in the groove so that the joint remains together.
(14) Install the K1 (1) clutch onto the B1 clutch
(Fig. 53).
(15) Install input shaft with clutch K2 (6) and
front gear set (1) (Fig. 53).
(16) Install front washer (5) and thrust needle
bearing (4) (Fig. 53).
(17) Install output shaft with center and rear gear
set and clutch K3 (3) (Fig. 53).
Fig. 53 Install K1, K2, and K3 Clutches
1 - DRIVING CLUTCH K1
5 - THRUST WASHER
2 - SUN GEAR OF FRONT PLANETARY GEAR SET
6 - FRONT PLANETARY GEAR SET, DRIVING CLUTCH K2, AND
INPUT SHAFT
3 - DRIVING CLUTCH K3, OUTPUT SHAFT, AND CENTER AND
REAR PLANETARY GEAR SETS
7 - SEALING RINGS
4 - THRUST NEEDLE BEARING
Fig. 54 Measure From Transmission Housing to
Park Gear
1 - GAUGE BAR 6311
2 - PARK GEAR
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(18) Using grease, install both Teflon rings in the
groove at the rear of the output shaft so that the
joint stays together.
(19) Mount transmission housing on converter
housing.
(20) Screw in Torx socket bolts through the trans-
mission housing into the converter housing. Tighten
the bolts to 20 N·m (177 in.lbs.).
(21) Measure end-play between park pawl gear
and grooved ball bearing in order to select the proper
geartrain end-play shim.
(22) Place Gauge Bar 6311 (1) on transmission
housing. Using a depth gauge, measure from the
gauge bar (1) to the parking lock gear (2) (Fig. 54).
(23) Using a depth gauge, measure from the
Gauge Bar 6311 (1) to the contact surface of the out-
put shaft bearing (2) in the transmission housing.
(Fig. 55)
(24) Subtract the first figure from the second fig-
ure to determine the current end-play of the trans-
mission. Select a shim such that the end-play will be
0.3-0.5 mm (0.012-0.020 in.). Shims are available in
thicknesses of 0.2 mm (0.008 in.), 0.3 mm (0.012 in.),
0.4 mm (0.016 in.), and 0.5 mm (0.020 in.).
(25) Install the selected end-play shim.
(26) Screw in Torx socket bolts through the con-
verter
housing
into
the
transmission
housing.
Tighten the bolts to 20 N·m (177 in.lbs.).
(27) Install output shaft bearing (2) in rear trans-
mission housing. Using Bearing Installer 9287 (1)
(Fig. 56), install the output shaft bearing (2) into the
transmission housing. The closed side of the plas-
tic cage must point towards the parking lock
gear.
(28) Install the retaining ring (1) (Fig. 57). Ensure
that the retaining ring is seated correctly in the
groove.
(29) Check that there is no play between the bear-
ing and the retaining ring using feeler gauge.
(30) There must be no play between the retaining
ring and the bearing. If the ring cannot be installed,
a thinner ring must be used. If there is play between
the ring and the bearing, a thicker ring must be
Fig. 55 Measure From Transmission Housing To
Rear Bearing Contact Surface
1 - GAUGE BAR 6311
2 - OUTPUT SHAFT BEARING CONTACT SURFACE
Fig. 56 Install Output Shaft Bearing
1 - BEARING INSTALLER 9287
2 - BEARING
3 - TRANSMISSION CASE
Fig. 57 Install Rear Output Shaft Retaining Ring
1 - RETAINING RING
2 - OUTPUT SHAFT BEARING
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AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION
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installed. Retaining rings are available in thick-
nesses of 2.0 mm (0.079 in.), 2.1 mm (0.083 in.), and
2.2 mm (0.087 in.).
(31) Rotate the transmission so that the bellhous-
ing is pointed upward and ensuring that the output
shaft is allowed to move freely.
(32) Measure input shaft end-play (Fig. 58).
NOTE: If end-play is incorrect, transmission is
incorrectly assembled, or the geartrain end-play
shim is incorrect. The geartrain end-play shim is
selective.
(a) Attach Adapter 8266-18 (2) to Handle 8266-8
(1).
(b) Attach dial indicator C-3339 (3) to Handle
8266-8 (1).
(c) Install the assembled tool onto the input
shaft of the transmission and tighten the retaining
screw on Adapter 8266-18 to secure it to the input
shaft.
(d) Position the dial indicator plunger against a
flat spot on the oil pump and zero the dial indica-
tor.
(e) Move input shaft in and out and record read-
ing. End play should be 0.3-0.5 mm (0.012-0.020
in.). Adjust as necessary.
(33) Install the output shaft washer onto the out-
put shaft.
(34) Install a new transmission rear seal into the
transmission case with Seal Installer 8902A (1) (Fig.
59).
(35) Place the transmission in PARK to prepare for
the installation of the output shaft nut.
(36) Install the propeller shaft flange onto the out-
put shaft and install an new flange nut. Tighten the
flange nut to 200 N·m (147.5 ft.lbs.).
(37) Place the Staking Tool 9078 (2) and Driver
Handle C-4171 onto the output shaft.
(38) Rotate the Staking Tool 9078 (2) until the
alignment pin (3) engages the output shaft notch (4)
(Fig. 60).
Fig. 58 Checking Input Shaft End Play
1 - TOOL 8266-8
2 - TOOL 8266-18
3 - TOOL C-3339
Fig. 59 Install Output Shaft Seal
1 - SEAL INSTALLER 8902A
2 - TRANSMISSION CASE
Fig. 60 Align Staking Tool 9078
1 - PROPELLER SHAFT FLANGE
2 - STAKING TOOL 9078
3 - ALIGNMENT PIN
4 - OUTPUT SHAFT NOTCH
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