Disassemble/assemble clutch K1 - AR27.51-P-0800B

TRANSMISSIONS 722.6

Fig 1: Disassembled View Of Clutch K1

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Assembly Tool And Snap Ring

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

25.8.98	New special tool for clearance adjustment		AR27.51-P-0800-02A
16.9.02	Disks for B1, K1 and K3 changed	Transmission 722.6 as from 02.09.02, see work step 12.	BT27.50-P-0013-01A

	Disassemble
1	Remove snap ring (90) from outer multiple-disc carrier
2	Take multiple-disc pack (89) out of outer multiple-disc carrier	Check multi-disks for scorch marks and wear.
3	Place assembly device (072) on spring plate (87) and tension until the snap ring (88) is exposed (figure A )	Assembly device	Fig 3
4	Remove snap ring (88)
5	Take out disk spring (86b) and remove piston (86) by carefully blowing compressed air into the bore (A) (figure B ).
6	Remove snap ring (91) and take out front freewheel (92).	According to condition.
	Assemble
7	Install piston (86) in outer multiple-disc carrier	Check sealing rings (83b and 86a), replace if necessary. The rounded off edges of the sealing rings must face outwards
8	Insert disc spring (86b).	Insert disk spring with the curvature towards the piston
9	Insert spring plate (87).	Insert spring cup with curvature towards sun gear.
10	Place assembly device (072) on spring plate (87) and tension until the groove of the snap ring is exposed	Assembly device Check sealing ring (87a), replace if necessary	Fig 3
11	Insert snap ring (88)	After installing, check snap ring for correct seating
12	Insert multiple-disc pack (89) in the outer multiple-disc carrier and measure	Observe externally-toothed plate sequence. Insert and measure disk pack K1: ↓
		Transmission 722.6 up to 01.09.02	AR27.51-P-0800-02A
		Thrust device	Fig 4
		Play in multiple-disc clutch K1	*BE27.51-P-1001-01B
		Transmission 722.6 as of 02.09.02	AR27.51-P-0800-02AA
		Thrust device	Fig 4
		Play in multiple-disc clutch K1	*BE27.51-P-1001-01B
	Strength of steel disks B1, K1 and K2 changed	Transmission 722.6	BT27.51-P-0002-01A
	Disks for B1, K1 and K3 changed	Transmission 722.6 as of 02.09.02	BT27.50-P-0013-01A
	Survey of multi-disk components, production details	Transmission 722.6	GF27.51-P-5200A
13	Insert snap ring (90)
14	Insert front freewheel (92) and fit snap ring (91)	The freewheel (92) must be installed in direction of arrow Continuing operation, see: ↓
14	Insert front freewheel (92) and fit snap ring (91)	Remove/install K1, K2 and K3	AR27.50-P-0621A

ADJUSTMENT VALUES OF MULTI-DISK CLUTCH

Number	Designation				Transmission 722.6 up to 01.09.02 with double sided multiple-discs	Transmission 722.6 as of 02.09.02 with single-sided multiple-discs
BE27.51-P-1001-01B	Play in multiple-disc clutch K1	Number of multiple-discs	3	mm	2.70...3.10	2.40...2.80
			4	mm	3.00...3.40	2.60...3.00
			5	mm	3.30...3.70	2.80...3.20
			6	mm	3.60...4.00	2.90...3.30

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

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Clamping Device (208 589 00 21 00)

Courtesy of MERCEDES-BENZ USA