Mercedes-Benz Sprinter / Dodge Sprinter. Service manual — part 450
(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 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 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 “L”
(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 “L”
(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
SET
12 - 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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(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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