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K1-Input Clutch: Assembly

Fig 1: Input Clutch K1 Components
GC0012805Courtesy of DAIMLERCHRYSLER CORP.
1 - K1 OUTER DISC CARRIER 7 - DISC SPRING
2 - FREEWHEELING CLUTCH F1 8 - SPRING PLATE
3 - SNAP-RING 9 - SPRING PLATE SEALING RING
4 - OUTER DISC CARRIER SEALING RING 10 - SNAP-RING
5 - PISTON SEALING RING 11 - SNAP-RING
6 - PISTON 12 - MULTIPLE DISC PACK - refer to step  6 for correct assembly order.
  1. Install piston (6) in the outer multiple-disc carrier (1). Check sealing rings (4 and 5), replace if necessary. The rounded off edges of the sealing rings must point outwards. See Fig 1.
  2. Insert disc spring (7). See Fig 1. Insert disc spring with the curvature towards the piston.
  3. Insert spring plate (8). Insert spring plate with the curvature towards the sun gear. Check sealing ring (9), replace if necessary.
    Fig 2: Compress Disc Spring
    GC0012806Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP-RING
    2 - MULTI-USE SPRING COMPRESSOR 8900
  4. Place Multi-use Spring Compressor 8900 (2) on spring plate and compress the spring until the groove of the snap-ring (1) is exposed. See Fig 2.
  5. Insert snap-ring (1). See Fig 1. After installing, check snap-ring for correct seat.
    Fig 3: Measure K1 Clutch Clearance
    GC0012808Courtesy of DAIMLERCHRYSLER CORP.
    1 - PRESSING TOOL 8901
    2 - K1 OUTER DISC CARRIER
    CAUTION: When working with double sided friction discs, an externally lugged steel plate is installed first, followed by a friction disc, and continuing on until all the required discs are installed. When working with single sided friction discs, an externally lugged disc is installed first, followed by an internally lugged disc, and continuing on until all the required discs are installed. All single sided discs are installed with the friction side up. 
    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 spring plate (8) to its original location.
    NOTE: Place new friction multiple-discs in ATF fluid for one hour before installing.
  6. Insert multiple-disc pack (12) in the outer multiple-disc carrier.
  7. Insert snap-ring (11).
  8. Measure the K1 clutch pack clearance by mounting Pressing Tool 8901 (1) on outer multiple disc. See Fig 3.
  9. 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 K1 Stack-up - Double Sided Discs
    GC0012807Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTER MULTIPLE DISC - 1.8MM (0.071 IN.)
    2 - OUTER MULTIPLE DISC - 2.8MM (0.110 IN.)
    3 - OUTER MULTIPLE DISC - 4.0MM (0.158 IN.)
    4 - K1 OUTER DISC CARRIER
    5 - SNAP-RING
    6 - FRICTION DISCS
    7 - DISC SPRING
    8 - PISTON
  10. For transmissions using double sided friction discs, use a feeler gauge to determine the play "L" at three points between the snap-ring (5) and outer multiple-disc (3). See Fig 4.
  11. During the measurement the snap-ring (5) must contact the upper bearing surface of the groove in the outer multiple-disc carrier (4).
  12. The correct clutch clearance for transmissions with double sided friction discs is 2.7-3.1 mm (0.106-0.122 in.) for three friction disc versions, 3.0-3.4 mm (0.118-0.134 in.) for four disc versions, 3.3-3.7 mm (0.130-0.146 in.) for five disc versions, and 3.6-4.0 mm (0.142-0.158 in.) for six disc versions.
  13. Adjust with snap-ring (5), if necessary. Snap-rings are available in thicknesses of 2.6 mm (0.102 in.), 2.9 mm (0.114 in.), 3.2 mm (0.126 in.), 3.5 mm (0.138 in.), 3.8 mm (0.150 in.), and 4.1 mm (0.162 in.).
  14. Insert front freewheeling clutch F1 (2) and fit snap-ring (3). The freewheeling clutch F1 (2) must be installed in the direction of the arrow.
    Fig 5: Input Clutch K1 Stack-up - Single Sided Discs
    GC0012809Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTER MULTIPLE DISCS
    2 - OUTER MULTIPLE DISC - 4.0MM (0.158 IN.)
    3 - K1 OUTER DISC CARRIER
    4 - SNAP-RING
    5 - INNER MULTIPLE DISCS
    6 - DISC SPRING
    7 - PISTON
  15. For transmissions using single sided friction discs, use a feeler gauge to determine the play "L" at three points between the snap-ring (4) and outer multiple-disc (2). See Fig 5.
  16. During the measurement the snap-ring (4) must contact the upper bearing surface of the groove in the outer multiple-disc carrier (3).
  17. The correct clutch clearance for transmissions with single sided friction discs is 2.4-2.8 mm (0.095-0.110 in.) for six friction disc versions, 2.6-3.0 mm (0.102-0.118 in.) for eight disc versions, 2.8-3.2 mm (0.110-0.126 in.) for ten disc versions, and 2.9-3.3 mm (0.114-0.130 in.) for twelve disc versions.
  18. Adjust with snap-ring (4), if necessary. Snap-rings are available in thicknesses of 2.6 mm (0.102 in.), 2.9 mm (0.114 in.), 3.2 mm (0.126 in.), 3.5 mm (0.138 in.), 3.8 mm (0.150 in.), and 4.1 mm (0.162 in.).
  19. Insert front freewheeling clutch F1 (2) and fit snap-ring (3). The freewheeling clutch F1 (2) must be installed in the direction of the arrow.
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