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2nd gear clutch Assembly, Disassemble and
Assemble
Illustration
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1
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Damping cushion, reverse gear clutch
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2
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Clutch plate (steel)
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3
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Clutch plate (lining)
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4
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Thrust ring for reverse gear clutch
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5
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Clutch drum, 2nd gear
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6
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Seal ring for clutch piston (inner)
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7
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Seal ring for clutch piston (outer)
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8
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Clutch piston, 2nd gear
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9
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Relief springs
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10
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Seat for relief springs
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11
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Retaining ring
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12
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Damping cushion, 2nd gear clutch
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13
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Clutch plate (steel) – x 6, V6 engines: x 7
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14
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Clutch plate (lining) – x 5, V6 engines: x 6
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15
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Damping cushion, 2nd gear clutch
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16
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Spacer sleeve, 2nd gear clutch
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17
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Retaining ring
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Illustration F 3129 shows assembly for 2nd and 3rd gear
clutch.
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18
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Internal gear
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19
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Retaining ring
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20
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Retaining ring
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21
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Thrust washer
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22
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Clutch drum, 3rd gear
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23
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Seal ring for clutch piston (inner)
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24
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Seal ring for clutch piston (outer)
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25
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Clutch piston, 3rd gear
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26
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Relief springs
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27
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Seat for relief springs
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28
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Retaining ring
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29
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Damping spring, 3rd gear
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30
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Clutch plate (steel) – x 5
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31
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Clutch plate (lining) – x 4
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32
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Clutch plate (lining) – only with V6 engines, special
plate with 4 recesses on the internal diameter of the friction
surface
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33
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Thrust washer
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34
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Axial needle bearing
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35
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Drive sun gear
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36
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Bearing race, overrunning clutch
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37
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Overrunning clutch
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38
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Bearing race, overrunning clutch
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39
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Race, overrunning clutch
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40
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Retaining ring
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41
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Axial needle bearing
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42
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Washer
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43
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Planetary carrier assembly
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 Remove
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Remove 2nd gear clutch assembly from transmission – see
operation "Assemblies, Remove and Install".
Disassemble
Remove 3rd gear clutch assembly (1) from 2nd gear clutch
assembly (2).
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Remove retaining ring (1) using a screwdriver and remove hollow
gear (2) from clutch drum.
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Disassemble
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Remove second retaining ring (1) using a screwdriver.
Remove spacer sleeve (2) from clutch drum.
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Remove clutch plates and damping
cushion from clutch drum.
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Damping cushion:
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x 2
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Steel plates:
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x 6, V6 engines: x 7
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Lining plates:
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x 5, V6 engines: x 6
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If clutch plates are not being replaced, install in original
position. See also "Technical Data" for number of steel and lining
plates.
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Disassemble
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Remove piston for 2nd gear clutch.
Attach KM-J-23078-A (1).
Caution
Use protective jaws on vice.
Disassemble
Clamp fastening nut (2) of clutch compressor in vice.
Turn clutch drum (compressing relief springs) until retaining
ring is free.
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Remove retaining ring (3) using KM-396 (1).
Relieve tension on KM-J-23078-A (2) and detach.
Remove seat (4) for relief springs.
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Remove thrust washer (1) and detach 22 relief springs (2) from
the clutch piston. Remove clutch piston (3) from clutch drum.
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Illustration
Components of 2nd gear clutch
| 1. |
Clutch drum |
| 2. |
Seal ring for clutch piston (inner) |
| 3. |
Seal ring for clutch piston (outer) |
| 4. |
Clutch piston |
| 5. |
Relief springs |
| 6. |
Seat for relief springs |
| 7. |
Retaining ring |
| 8. |
Damping cushion (corrugated washer) |
| 9. |
Clutch plate (steel) |
| 10. |
Clutch plate (lining) |
| 11. |
Spacer sleeve |
| 12. |
Retaining ring |
| 13. |
Internal gear |
| 14. |
Retaining ring |
| 15. |
Thrust washer |
| 16. |
Thrust washer (installed on clutch drum for 3rd
gear) |
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Assemble
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Before assembling, check all components of 2nd gear clutch for
wear or damage, replace with new parts, if necessary.
Inspect
Replace inner and outer seal ring on clutch piston (1).
Sealing lip of seal rings face towards piston crown.
By shaking the clutch piston check whether the valve ball
(arrow) is fitted and can move freely. If the valve ball is missing
or has fallen out, replace the clutch piston.
Push KM-J-23080-A (2) onto clutch piston to protect sealing lip
on outer seal ring (3).
Note: The inner seal
ring is seated on clutch drum hub and is not damaged during
installation of clutch piston.
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Assemble
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Install clutch piston in conjunction with KM-J-23080-A (1) in
clutch drum. Coat sealing lips of seal rings for this purpose with
transmission fluid or installation grease.
Remove KM-J-23080-A.
Caution
If one relief spring is defective, replace all relief
springs.
Assemble
Insert release springs (4) in clutch piston.
Insert seat (3) for release springs and retaining ring (2).
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Attach KM-J-23078-A (2) and compress relief springs until
retaining ring (3) can be inserted into groove with KM-396 (1).
Install retaining ring. Ensure it is correctly seated.
Detach KM-J-23078-A.
Insert damping cushion (4) and steel plate (5) into clutch
drum.
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Caution
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Immerse lining plates in transmission fluid for about 20 minutes
beforehand. Insert 2nd damping cushion between last lining plate
and spacer sleeve.
Assemble
Insert lining plates and steel plates into clutch drum
alternately.
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Insert spacer sleeve (1) with corrugated side towards clutch
piston.
Install retaining ring (2). Ensure it is correctly seated.
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Caution
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Notch on flank (2) of hollow gear faces outwards.
Assemble
Install hollow gear (1) in clutch drum.
Install retaining ring (3). Ensure it is correctly seated.
Insert thrust washer (4) between 2nd and 3rd gear clutch with
installation grease.
The installation position is determined by guide lugs. On
insertion, use installation grease in order to fix position.
Install
Install 2nd gear clutch assembly in transmission – see
operation "Assemblies, Remove and Install".
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