Dismantling and assembling drive shaft with clutch K2 and front gear set - AR27.51-P-0825A

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TRANSMISSION 722.6

Fig 1: Identifying Drive Shaft With Clutch K2 And Front Gear Set Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Snap Ring, Assembly Device

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Modification notes

1.8.97	New assembly device	Special tool for steps 8 and 13 modified
25.8.98	New special tool for setting loose play		AR27.51-P-0820-02A

	Disassembling
1	Detach transmission housing from torque converter housing, fit on		AR27.50-P-0601A
2	Remove multiple-disk clutch K1, K2 and K3, install		AR27.50-P-0621A
3	Remove snap ring (84b) from the inner multiple-disc carrier / clutch K1 with integrated front gear set (84) and take off hollow gear (84a)
	Conversion from 18° to 23° teeth in front and rear planetary gear set	Transmission 722.6	BT27.50-P-0012-01A
4	Remove drive shaft with clutch K2 (100)
	Plain bearings of input shaft converted to anti-friction bearings	Transmission 722.6	BT27.50-P-0002-02A
5	Remove needle thrust bearing (85)
6	Remove snap ring (106) from outer multiple-disc carrier / clutch K2
7	Take out multiple-disc pack (105)	Inspect disks for scorch points and wear
8	Take out disk spring (107)	As of transmission no. 1596205
	Additional disk spring in multiple-disk set K2	Transmission 722.6	BT27.51-P-0003-01A
9	Fit assembly device (076) onto spring retainer (103) and press until snap ring (104) is released (Fig. A)		Figure
9		Operate assembly device with a lever press.	Figure
10	Remove snap ring (104)
11	Take out disc spring (102) and pull piston (101) out of outer multiple-disc carrier	Further work according to condition: ↓
11		Remove multiple-disk brake B1 and oil pump, install	AR27.50-P-0721A
	Assembling
12	Install piston (101) in outer multiple-disc carrier	Inspect seals (101a and 101b), replace if necessary. The rounded edges of the seals must point to the outside.
13	Insert disk spring (102) and spring retainer(103)	Insert disk spring (102) with curved side pointing toward spring retainer (103). Inspect seal (103a), replace if necessary.
14	Place assembly device (076) on spring plate (103) and press until the groove of the snap ring is exposed		Figure
15	Insert snap ring (104)
16	Insert disk spring (107).	As of transmission no. 1596205
	Additional disk spring in multiple-disk set K2	Transmission 722.6	BT27.51-P-0003-01A
17	Insert multiple-disk set (105) into outer multiple-disk carrier and measure	Pay attention to order of outer disks.	AR27.51-P-0820-02A
	Thickness of steel disks B1, K1 and K2 modified	Transmission 722.6	BT27.51-P-0002-01A
	Survey of disks fitted as-built configuration	Transmission 722.6	GF27.51-P-5200A
18	Fit snap ring (106)
19	Insert axial needle bearing (85) into inner multiple-disk carrier/K1	Insert axial needle bearing (85) with a little grease to prevent it slipping.	*BR00.45-Z-1007-06A
20	Install drive shaft in inner multiple-disc carrier/ clutch K1 with integrated front gear set
21	Fit internally-geared wheel (84a)	Pay attention to installation position.
		Further work: ↓
		Remove multiple-disk clutch K1, K2 and K3, install	AR27.50-P-0621A

Fig 3: Identifying Assembly Device (140 589 13 43 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Repair materials

Number	Designation	Order number
BR00.45-Z-1007-06A	Grease	A 001 989 37 51