Disassembly
Details of the installation of the components of the input shaft with the K2 clutch and the front planetary gear set
84 - Internal clutch support K1 with integrated front planetary gear set; 84a - Gear; 84b, 104, 106 - Retaining rings; 85 - Thrust needle bearing; 100 - Drive shaft with clutch K2; 101 - Piston; 101a - Piston inner seal 101b - Piston outer seal; 102, 107 - Disc springs; 103 - Spring retainer; 103a - Spring retainer seal; 105 - Disc block
1. Disconnect the transmission housing from the torque converter housing.
2. Remove clutches K1, K2 and K3.
3. Remove retaining ring (84b) from inner clutch support K1 (84) and remove the gear (84a) (see resist. illustration).
4. Remove the drive shaft with clutch K2 (100).
5. Remove the needle thrust bearing (85).
6. Remove retaining ring (106) from the outer clutch support K2.
7. Remove the drive unit (105).
8. Remove disc spring (107).
9. Install the puller (076) on a spring clip (103) and press it until the retaining ring (104) will not be released.
10. Remove retaining ring (104).
11. Remove disc spring (102) and remove the piston (101) from the outer support.
Assembly
Checking the gap between the circlip (90) and outer disc (89c)
100a - Outer clutch support K2; 101 - Piston; 105a - Outer disc 1.8 mm thick; 105b - Outer disc 3.5mm thick/new 2.8mm thick; 105c - Outer disc 4.0 mm thick; 105d - Friction discs; 106 - Retaining ring; 107 - Disc spring; L - Gap
Assembly is carried out in the reverse order of disassembly. Check clearance between retaining ring (106) and outer disc (105c). The size of the gaps in the clutch K2 is shown in the table below. If necessary, adjust the gap by selecting the retaining ring (106) required thickness. Rings are available in thicknesses of 2.3, 2.6, 2.9, 3.2, 3.5 and 3.8 mm.