Mercedes-Benz Sprinter / Dodge Sprinter. Service manual — part 464

(2) Assemble piston guide (4) (Fig. 178) and B3

piston (8) in the correct position. Verify that the
missing tooth in the B3 piston/B2 outer disc carrier
(8) is aligned with the centerline of the two threaded
holes in the B2 and B3 piston guide (4).

(3) Insert B2 piston (10) (Fig. 178) in B3 piston

(8).

Fig. 178 Holding Clutch B2

1 - SNAP-RING

9 - B2 PISTON SEALING RING

2 - MULTIPLE DISC PACK

10 - B2 PISTON

3 - DISC SPRING

11 - PISTON GUIDE SEALING RING

4 - B2 AND B3 PISTON GUIDE

12 - PISTON GUIDE SEALING RING

5 - O-RING

13 - PISTON GUIDE RING

6 - B3 PISTON SEALING RING

14 - PISTON BACK PRESSURE DISC SPRING

7 - B3 PISTON SEALING RING

15 - SPRING PLATE

8 - B3 PISTON/B2 OUTER DISC CARRIER

16 - SNAP-RING

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(4) Insert piston guide ring (2) (Fig. 179). The

valve (1) in the piston guide ring must be on top.

(5) Insert disc spring (14) (Fig. 178) and spring

plate (15). Insert disc spring with the curvature
towards the spring plate

(6) Place Multi-use Spring Compressor 8900 on the

disc spring (14) and compress the spring until the
groove for the snap-ring is exposed.

(7) Insert snap-ring (16).

NOTE: Pay attention to 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 (3) to its original location.
Place new friction multiple-discs in ATF fluid for
one hour before installing.

(8) Insert disc spring (3) and multiple-disc pack (2)

in the B2 outer multiple-disc carrier.

(9) Insert snap-ring (1).

NOTE: During the measurement the snap-ring (8)
must contact the upper bearing surface of the
groove in the outer multiple-disc carrier.

(10) Measure the B2 clutch pack clearance by

mounting the Pressing Tool 8901 (1) (Fig. 180) on
outer multiple disc.

(11) Using a lever press, compress the pressing

tool as far as the stop (then the marking ring is still
visible, see small arrow).

Fig. 179 B2 Piston and Piston Guide Ring

1 - VALVE
2 - PISTON GUIDE RING
3 - B2 PISTON

Fig. 180 Measure B2 Clutch Clearance

1 - PRESSING TOOL 8901
2 - B3 PISTON/B2 OUTER DISC CARRIER

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(12) Using a feeler gauge, determine the play “L”

(Fig. 181) at three points between the snap-ring (8)
and outer multiple-disc (7).

(13) The correct clutch clearance is 1.9-2.3 mm

(0.075-0.091 in.) for the four friction disc versions
and 2.0-2.4 mm (0.079-0.095 in.) for the five disc ver-
sions.

(14) Adjust with snap-ring (8), if necessary. Snap-

rings are available in thicknesses of 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.).

INPUT SPEED SENSORS

DESCRIPTION

The input speed sensors (6, 8) (Fig. 182) are fixed

to the shell of the control unit via contact blades. The
speed sensors are pressed against the transmission
housing (2) by a spring (7) which is held against the
valve housing of the shift plate (5). This ensures a
defined distance between the speed sensors and the
exciter ring (4).

Fig. 181 B2 Clutch Stack-up

1 - B2 OUTER DISC CARRIER
2 - FRICTION DISCS
3 - DISC SPRING
4 - B2 PISTON
5 - OUTER MULTIPLE DISC - 1.8 MM (0.071 IN.)
6 - OUTER MULTIPLE DISC - 1.8 MM (0.071 IN.)
7 - OUTER MULTIPLE DISC - 6.5 MM (0.256 IN.)
8 - SNAP-RING

Fig. 182 Speed Sensors

1 - DRIVING CLUTCH K1
2 - TRANSMISSION HOUSING
3 - DRIVING CLUTCH K1 INTERNALLY TOOTHED DISC
4 - EXCITER RING
5 - VALVE HOUSING OF SHIFT PLATE
6 - N2 INPUT SPEED SENSOR
7 - SPRING
8 - N3 INPUT SPEED SENSOR
9 - EXCITER RING
10 - DRIVING CLUTCH K1 EXTERNALLY TOOTHED DISC

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OPERATION

Signals from the input speed sensors (6, 8) (Fig.

183) are recorded in the transmission control module
(TCM) together with the wheel and engine speeds
and other information and are processed into an
input signal for electronic control.

Input speed sensor N2 (6) records the speed of the

front sun gear via the externally toothed disc carrier
of the multiple-disc clutch K1 (10) and input speed
sensor N3 (8) records the speed of the front planet
carrier via the internally toothed disc carrier of mul-
tiple-disc clutch K1 (3).

OIL PUMP

DESCRIPTION

The oil pump (2) (Fig. 184) (crescent-type pump) is

installed in the bellhousing behind the torque con-
verter and is driven by the drive flange of the torque
converter. The pump creates the oil pressure required
for the hydraulic procedures.

OPERATION

When the engine is running, the oil (Fig. 185) is

pumped through the inlet chamber (5) along the

Fig. 183 Input Speed Sensors

1 - DRIVING CLUTCH K1
2 - TRANSMISSION HOUSING
3 - DRIVING CLUTCH K1 INTERNALLY TOOTHED DISC
4 - EXCITER RING
5 - VALVE HOUSING OF SHIFT PLATE
6 - N2 INPUT SPEED SENSOR
7 - SPRING
8 - N3 INPUT SPEED SENSOR
9 - EXCITER RING
10 - DRIVING CLUTCH K1 EXTERNALLY TOOTHED DISC

Fig. 184 Oil Pump

1 - CRESCENT
2 - OIL PUMP
3 - EXTERNAL GEAR
4 - INTERNAL GEAR
5 - INLET CHAMBER
6 - PRESSURE CHAMBER

Fig. 185 Oil Pump

1 - CRESCENT
2 - OIL PUMP
3 - EXTERNAL GEAR
4 - INTERNAL GEAR
5 - INLET CHAMBER
6 - PRESSURE CHAMBER

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