Clutch, K2: Assembly
WARNING: This page is about a different variant/trim than selected.
NOTE:
If either the electro-hydraulic control unit or transmission is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the TCM Adaptation Procedure using the scan tool (Refer to TRANSMISSION CONTROL MODULE (TCM) ADAPTATION - NAG1 .
| 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 |
- Install piston (9) in outer multiple-disc carrier. Inspect seals (6 and 7), replace if necessary. The rounded edges of the inner piston seal (7) must point to the outside.
- Insert disk spring (10) and spring retainer (12). Insert disk spring (10) with curved side pointing toward spring retainer (12). Inspect seal (11), replace if necessary.
1 - MULTI-USE SPRING COMPRESSOR 8900 2 - SNAP-RING - Place Multi-use Spring Compressor (special tool #8900A, Multi Use Spring Compressor) (1) on spring plate and press until the groove (2) of the snap-ring is exposed.
- Insert snap-ring.
- Insert disk spring (14).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 disc spring (14) to its original location.
- Insert multiple-disk set (16) into outer multiple-disk carrier.
- Fit snap-ring (17).
1 - PRESSING TOOL 8901A 2 - K1 INNER DISC CARRIER - Measure K2 clutch clearance by mounting Pressing Tool 8901A (1) on outer multiple disc.
- Using a lever press, compress pressing tool to the upper most line marked 1200 N (the marking ring is still visible, see small arrow).
1 - DISC SPRING 2 - OUTER MULTIPLE DISC - 1.8 MM (0.071 IN.) 3 - OUTER MULTIPLE DISC - 3.5 MM (0.138 IN.) 4 - OUTER MULTIPLE DISC - 4.0 MM (0.158 IN.) 5 - K2 OUTER DISC CARRIER 6 - SNAP-RING 7 - FRICTION DISCS 8 - PISTON - Using a feeler gauge, determine the play "L" at three points between the snap-ring (6) and outer multiple-disc (4).
- During the measurement the snap-ring (6) must contact the upper bearing surface of the groove in the outer multiple-disc carrier.
- The correct clutch clearance is 2.3-2.7 mm (0.091-0.106 in.) for three friction disc versions, 2.4-2.8 mm (0.095-0.110 in.) for four disc versions, 2.5-2.9 mm (0.099-0.114 in.) for five disc versions, and 2.7-3.1 mm (0.106-0.122 in.) for six disc versions.
- Adjust with snap-ring (6), if necessary. Snap-rings are available in thicknesses of 2.3 mm (0.091 in.), 2.6 mm (0.102 in.), 2.9 mm (0.114 in.), 3.2 mm (0.126 in.), 3.5 mm (0.138 in.), and 3.8 mm (0.150 in.).
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 - Insert axial needle bearing (3) into K1 inner multiple-disk carrier. Insert axial needle bearing (3) with a little grease to prevent it slipping.
- Install input shaft in K1 inner multiple-disc carrier with integrated front gear set (2).
1 - Item_1 2 - Item _2 NOTE:Insure that the Hollow Gear (18) is oriented during installation such it protrudes from the K2 Retainer.
- Fit internally-geared wheel (18) and install snap-ring.