Removal, installation and inspection of BS overdrive brake and KS clutch components (Mercedes-Benz S-Class W140)

Removal

1. Remove the rear gearbox cover.

2. Remove the drive shaft (86) by removing the retaining ring (165).

3. Remove the ring gear (170). Remove the shims (166) and thrust bearing (169) from the output shaft (167). Remove the planet carrier (168) from the ring gear (170).



4. Remove the sun gear (171) and ring gear (170).





5. Remove the overdrive clutch (172) from the disc block.

6. Remove the overdrive brake disc assembly from the housing by removing the retaining ring (186).

7. Remove the damper spring (195). Remove the locking ring (190) and cam spring (191).



8. Using pliers, remove the overdrive brake piston (192) from the housing, remove the Teflon rings (196), and then the thrust washer (173).

Installation

1. Before installing the thrust washer (173), make sure that the lubrication hole (arrow) is installed in the gearbox housing.



2. Lubricate both sealing rings of the overdrive brake piston (192) with transmission oil, press the piston into the housing, insert the thrust washer (173) so that the anti-rotation edge is located in the housing, screw in the Teflon rings (196).



3. Insert the cam spring (191), install the locking ring (190), install the damper spring (195). Install the overdrive brake discs individually.



4. Carefully insert the overdrive clutch support (17) into the overdrive multi-disc brake.





5. Carefully insert the ring gear (170) into the overdrive brake.



6. Insert the sun gear (171).



7. Insert the carrier (168) into the ring gear (170), make sure that the inner thrust bearing (169) grabs the carrier, secure the outer thrust bearing (169), install the shims (166) on the output shaft (167).

Checking the axial clearance between the output and intermediate shafts

1. Measure the distance "a" from the contact surface of the output shaft bearing (86) to the inner ring of the bearing (198) using a caliper.



2. Determine the distance "b" from the shims (166) to the thrust roller bearing (169) using a caliper.



3. Adjust the axial clearance "c" with shims (166), determining the thickness of the shim:



Distance "a" (18.00 mm) - Distance "b" (16.60 mm) = Difference (1.40 mm) - Axial clearance (0.10 mm) - Gasket thickness (1.30 mm).

The axial clearance between the output and intermediate shafts is 0.10 mm. Gaskets with a thickness of 0.1, 0.2 and 0.5 mm are produced.

4. Install the output shaft (86) and insert the locking ring (165).

Checking the axial clearance between the output shaft and the rear cover

1. Measure the distance "a" by placing the measuring disc (028) on the contact surface of the rear cover. Determine the distance from the disc (028) to the inner race of the ball bearing (67) using a caliper.



2. Install the measuring disc (028) and flange. Lock the parking brake pawl in the operating position. Tighten the nut (62) to 100 Nm. Install the gasket (72).





3. Measure the distance "b" between the measuring disk (028) and the gasket (72).



4. Adjust the axial clearance "E" with shims:

Distance "a" (118.80 mm) - Distance "b" = Difference (1.90 mm) - Axial clearance "E" (0.40 mm) = Gasket thickness (1.50 mm).

The nominal value of the axial clearance between the output shaft and the rear cover is 0.40 mm. Gaskets with a thickness of 0.5, 0.6, 0.7, 0.8 and 0.9 mm are produced.

5. Remove the measuring disc and flange.

Checking the clearance in the overdrive brake

1. Measure the clearance "S". The nominal value of the overdrive brake clearance is within the range of 0.5-1.1 mm. Adjust it, if necessary, using the retaining ring shims (186). The shims are available in thicknesses of 2.0, 2.5 and 3.0 mm.

2. Install the gearbox rear cover.