Disassembly and assembly of the K1 clutch (Mercedes-Benz S-Class W140)

Disassembly

1. Remove the retaining ring (11) from the outer support of the outer clutch discs (1).

2. Remove the discs (6), (7), (8), (10) and the disc spring (15). Check the discs for wear and damage.

3. Place the puller (020) on the spring sleeve (4) and compress it until the retaining ring (5) is released.

4. Remove the retaining ring (5).

5. Remove the spring bushing (4) from the spring (3).

6. Remove the piston (2) from the caliper (1).

7. Remove the sealing rings (12) and (13) from the piston.

8. Remove the retaining ring (16) from the outer disc caliper (1).

9. Remove the piston guide ring (18).

10. Remove the sealing ring (17).

Assembly

1. Install a new sealing ring (17).

2. Install the piston guide ring (18).

3. Install the retaining ring (16) into the outer disc caliper (1).



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4. Insert the sealing rings (12) and (13) into the piston (2), - the sealing edges must be facing downwards (in the direction of the arrows); install bushings (021) and (022) into the outer disc support (1).

5. Lubricate the bushings and sealing rings with transmission fluid, carefully insert the piston (2) and press it into the outer disc caliper (1) without tilting.



6. Install the spring bushing (4) and springs (3).

7. Install the puller (020) on the spring sleeve (4) and compress it.

8. Install the retaining ring (5).

9. Install the disc spring (15) and discs (6), (7), (8) and (10) into the caliper (1).

10. Install the retaining ring (11). After installation, press the retaining ring upwards along the periphery until it is fully seated.

Checking the gap

Measure the gap "A" and adjust it if necessary by selecting the retaining ring (11) of the required thickness (see illustration 20.1). The nominal value of the gap "A" in the K1 clutch is within the range of 0.7-1.3 mm. Retaining rings of 2.0, 2.6 and 3.0 mm thickness are produced.