Clutch "D/E" , disassembling and assembling
Disassembling clutch "E"
- Remove cylinder "D/E" - 2 - from planetary gear - 1 -.
- Twist cylinder "D/E" - 1 -.
- Remove axial needle bearing "2" from clutch - E -.
- Remove circlip - 1 - and remove disc pack - 2 - from cylinder "E".
- Press dished washer down under shop press using installation bracket T10276.
- Remove split retaining ring - 1 - and release shop press.
- Remove dished washer.
CAUTION:
Wear protective glasses.
- Carefully press piston "E" out of cylinder "E" with compressed air.
- Carefully strike on bearing sleeve to drive out of cylinder "D/E" all around.
Disassembling clutch "D"
- Twist cylinder "D/E" - 1 -.
- Remove bushing - 3 - from cylinder "D/E".
- Remove circlip - 1 - and remove disc pack - 2 - from cylinder "D".
- Press dished washer down under shop press using installation bracket T10278.
- Remove circlip - 1 - and release shop press.
- Remove dished washer.
CAUTION:
Wear protective glasses.
- Carefully press piston "D" out of cylinder "D" with compressed air.
Assembling clutch "D"
CAUTION:
Check individual components of clutch "D" for wear and damage →
Clutch "C" with sun shaft .
- Replace O-rings - 2 - on bushing - 3 -.
- Press bushing - 3 - in cylinder "D/E" - item 1 -.
- Replace O-rings - 2 - and - 4 - for piston "D" - item 3 -.
- Press piston "D" - 3 - into cylinder "D" - 1 - until stop.
- Position dished washer - 5 -.
6 - Circlip
- Press dished washer down under shop press using installation bracket T10278.
- Insert circlip - 1 -.
- Bent inner side at right angle of circlip faces downward.
- Make sure that circlip is seated evenly all around in groove of cylinder "D/E" , if necessary, press circlip into groove all around using screwdriver.
- Release shop press.
- Insert wave washer - 2 - into cylinder "D" - item 1 -.
- Install outer plate - 3 - and coated plate - 4 - alternately (3, 4 or 5 outer and coated plate, depending on transmission).
- Install thick outer plate - 5 -.
- Insert circlip - 6 -.
Adjust air gap clutch "D"
- Place cylinder "D/E" on pre-tensioning tool T10285.
- Clutch "D" faces upward.
- Position plate T10281 on outer clutch plate "D".
- Plate must not touch circlip.
- Insert pressure unit T10285/1 with centering pin into bore of plate.
- Align cylinder "D/E" on plate of pre-tensioning tool.
- The pressure unit must be centrally positioned under spindle thrust piece.
- Turn spindle of pre-tensioning tool downward.
- The markings at the inspection hole of the pressure unit must align - arrow -.
- Apply Digital depth gauge VAS 6087 at upper edge of cylinder "D/E" , as depicted in illustration.
- Apply measuring tongue on outer plate to measuring value.
- Mark contact point on cylinder "D/E".
- Repeat measurement at 2 other points of outer plate, 120 ° offset each, and mark contact points.
- Average over 3 measured values under load.
- Release spindle and remove plate.
- Reach with both hands into clutch "D" and pull disc pack upward until stop.
- When disc pack is pulled up, measure distance between upper edge of cylinder "D/E" and outer plate (2nd technician required) at one of the marked points.
- Repeat measurement at 2 other marked points of outer plate.
- Average over 3 measured values when disc pack is pulled up.
- Determine air gap on basis of the following calculations:
| Average of measured values under load (value 1 + value 2 + value 3): 3 | |
| Measurement when disc pack is pulled up (value 1 + value 2 + value 3): 3 | |
| = | Air gap |
- Subtract average of measured values when disc pack is pulled up from average of measured values under load.
Air gap clutch "D" for transmission with code letters CUE, DPZ, DSL, DSM, DTD, DTE, DYM, ECX:
- With 4 coated plates: 1.35 to 1.65 mm.
Air gap clutch "D" for transmission with code letters ECY, ECZ and the following:
- With 4 coated plates: 1.55 to 1.85 mm.
- With 5 coated plates: 1.93 to 2.22 mm.
If specified value is not obtained:
- Determine new circlip - 1 -.
NOTE:
- Disregard - 2 -.
- Measured value too small: Install respectively thinner circlip.
- Measured value too large: Install respectively thicker circlip.
The following circlips are available:
| Available circlips in mm | ||
| 2.4 | 3.2 | 4.0 |
| 2.6 | 3.4 | 4.2 |
| 2.8 | 3.6 | |
| 3.0 | 3.8 | |
- Check air gap of circlip again after inserting.
Assembling clutch "E"
CAUTION:
Check individual components of clutch "E" for wear and damage →
Clutch "C" with sun shaft .
- Twist cylinder "D/E".
- Clutch "E" faces upward.
- Insert O-ring - 2 - into cylinder "E" - item 1 -.
- Insert O-ring - 4 - into piston "E" - item 3 -.
- Insert piston "E" into cylinder "E".
- Position dished washer - 5 -.
6 - Split retaining ring
- Press dished washer down under shop press using installation bracket T10276.
- Install split retaining ring - 1 -.
- Bent inner side at right angle of split retaining ring faces downward.
- Release shop press.
- Insert wave washer - 2 -.
- Install outer plate - 3 - and coated plate - 4 - alternately (4 or 5 outer and coated plate each, depending on transmission).
- Install thick outer plate - 5 -.
- Insert circlip - 6 -.
Adjust air gap clutch "E"
- Place cylinder "D/E" on pre-tensioning tool T10285.
- Clutch "E" faces upward.
- Position plate T10281 on outer plate clutch "E".
- Plate must not touch circlip.
- Insert pressure unit T10285/1 with centering pin into bore of plate.
- Align cylinder "D/E" on plate of pre-tensioning tool.
- The pressure unit must be centrally positioned under spindle thrust piece.
- Turn spindle of pre-tensioning tool downward.
- The markings at the inspection hole of the pressure unit must align - arrow -.
- Apply Digital depth gauge VAS 6087 at upper edge of cylinder "D/E" , as depicted in illustration.
- Apply measuring tongue on outer plate and note measuring value.
- Mark contact point on cylinder "D/E".
- Repeat measurement at 2 other points of outer plate, 120 ° offset each, and mark contact points.
- Average over 3 measured values under load.
- Release spindle and remove plate.
- Reach with both hands into clutch "E" and pull disc pack upward until stop.
- When disc pack is pulled up, measure distance between upper edge of cylinder "D/E" and outer plate (2nd technician required) at one of the marked points.
- Repeat measurement at 2 other marked points of outer plate.
- Average over 3 measured values when disc pack is pulled up.
- Determine air gap on the basis of the following calculations:
| Average of measured values under load (value 1 + value 2 + value 3): 3 | |
| Measurement when disc pack is pulled up (value 1 + value 2 + value 3): 3 | |
| = | Air gap |
- Subtract average of measured values when disc pack is pulled up from average of measured values under load.
Air gap clutch "E" for transmission with code letters CUE, DPZ, DSL, DSM, DTD, DTE, DYM, ECX:
- With 4 coated plates: 1.1 to 1.4 mm.
- With 5 coated plates: 1.4 to 1.7 mm.
Air gap clutch "E" for transmission with code letters ECY, ECZ and the following:
- With 4 coated plates: 1.55 to 1.85 mm.
- With 5 coated plates: 1.93 to 2.10 mm.
If specified value is not obtained:
- Determine new circlip - 1 -.
NOTE:
- Disregard - 2 -.
- Measured value too small: Install respectively thinner circlip.
- Measured value too large: Install respectively thicker circlip.
The following circlips are available:
| Available circlips in mm | ||
| 2.2 | 2.8 | 3.4 |
| 2.4 | 3.0 | 3.6 |
| 2.6 | 3.2 | 3.8 |