K2-Input Clutch: Assembly

Fig 1: Exploded View Of Input Clutch K2 Components

Courtesy of DAIMLERCHRYSLER CORP.

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. See Fig 1.
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. See Fig 1.

Fig 2: Compressing K2 Clutch Spring
Courtesy of DAIMLERCHRYSLER CORP.

1 - MULTI-USE SPRING COMPRESSOR 8900

2 - SNAP-RING
Place Multi-use Spring Compressor 8900 (1) on spring plate and press until the groove (2) of the snap-ring is exposed. See Fig 2.
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).

Fig 3: Measure K2 Clutch Clearance
Courtesy of DAIMLERCHRYSLER CORP.

1 - PRESSING TOOL 8901

2 - K1 INNER DISC CARRIER
Measure K2 clutch clearance by mounting Pressing Tool 8901 (1) on outer multiple disc. See Fig 3.

Using a lever press, compress pressing tool as far as the marking ring (the marking ring is still visible, see small arrow).

Fig 4: Input Clutch K2 Stack-up

Courtesy of DAIMLERCHRYSLER CORP.

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). See Fig 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.).

Fig 5: Exploded View Of Input Clutch K2 Components

Courtesy of DAIMLERCHRYSLER CORP.

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. See Fig 5.
Install input shaft in K1 inner multiple-disc carrier with integrated front gear set (2).
Fit internally-geared wheel (18) and install snap-ring (19). Pay attention to installation position.