Disassemble/assemble K2 clutch

AR27.51-S-0820PS

23.05.2018

Transmission

722.9 in model 470, 471 with engine 642

P27.51-2029-09

1a	Torlon rings	11	Drive shaft	11s	Retaining ring
2d	Thrust bearing	11f	Spring retainer	11t	Disk spring
5	Clutch pack	11k	Piston	105	End disk
5t	Disk spring	11l	Radial bearing	105s	Retaining ring

076	Assembly device
104	Retaining ring groove

P27.51-0210-02

 Caution	Risk of injury to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil	Wear protective gloves, protective clothing and safety glasses. Do not pour transmission oil into beverage bottles.	AS00.40-Z-0001-01A
Topical note	General information on repair work on transmission		AH27.00-S-1000-01PS
	Remove
1	Remove clutch K2.		AR27.50-S-0612PS
	Disassemble
2	Remove radial bearing (11l).
3	Remove Torlon rings (1a).
4	Remove axial bearing (2d).
5	Remove retaining ring (105s).	 Pliers	*000589523700
6	Remove end disk (105).
7	Remove clutch pack (5).
8	Remove disk spring (5t).
9	Place drive shaft (11) in lever-type hand gun.
10	Fit assembly device (076) on spring retainer (11f).	 Assembly device	*140589134300
11	Actuate lever-type hand gun until retaining ring (11s) is exposed.	 Stop lever press stroke as soon as accessibility is sufficient. Excess force can cause damage.
12	Remove retaining ring (11s).	 Pliers	*000589523700
13	Reset hand lever press.
14	Remove assembly device (076) from lever-type hand gun.
15	Remove drive shaft (11) from lever-type hand gun.
16	Remove spring retainer (11f).
17	Remove sealing ring of spring retainer (11f).	 Assembly tool	*000589936300
18	Remove disk spring (11t).
19	Remove piston (11k).
20	Remove sealing ring from piston (11k).	 Assembly tool	*000589936300
	Check
21	Check radial bearing (11l) for damage.	If damage is visible,
		
		Replace radial bearing (11l).
22	Check axial bearing (2d) for damage.	If damage is visible,
		
		replace axial bearing (2d).
23	Check radial bearing (arrow) in output shaft guide for damage.	If damage is visible,
		
		replace radial bearing (arrow).
		 Pay attention to installation position.
24	Check clutch pack (5) for scorch marks and wear.	If scorch marks or worn disks are visible,
		
		Replace disks of clutch pack (5).
25	Check drive shaft (11) for wear and damage.	If traces of wear or damage are visible,
		
		replace drive shaft (11).
	Assemble
26	Lie new disks in transmission oil for at least one hour.	When replacing.
	Automatic transmission fluids (ATF) (specification 236.15)		BB00.40-P-0236-15A
27	Attach new sealing ring to piston (11k).	 Assembly tool	*000589936300
28	Install piston (11k).
29	Install disk spring (11t).	 Insert disk spring (11t) in such a way that curvature of inner circumference points toward spring retainer (11f).
30	Attach new sealing ring to spring retainer (11f).	 The rounded edge of the sealing ring must face outwards.
		 Assembly tool	*000589936300
31	Fit spring retainer (11f).
32	Place drive shaft (11) in lever-type hand gun.
33	Fit assembly device (076) on spring retainer (11f).	 Assembly device	*140589134300
34	Actuate lever-type hand gun until retaining ring groove (104) is exposed.	 Stop lever press stroke as soon as accessibility is sufficient. Excess force can cause damage.
		 To prevent tilting, position spring retainer (11f) precisely. Otherwise, the transmission components will be damaged.
35	Install retaining ring (11s).	 Pliers	*000589523700
36	Reset hand lever press.
37	Remove assembly device (076) from lever-type hand gun.
38	Remove drive shaft (11) from lever-type hand gun.
39	Install disk spring (5t).	 Insert disk spring (5t) in such a way that curvature of inner circumference points toward piston (11k).
40	Install clutch pack (5).
41	Install end disk (105).
42	Install retaining ring (105s).	 Pliers	*000589523700
	Measure
43	Measure and adjust clearance of clutch pack (5).		AR27.51-S-7229-02PS
		Play in multiple-disc clutch K2	*BE27.51-N-1002-01C
		 Pliers	*000589523700
		 Parallel rest	*126589043100
		 Pressing tool	*722589013100
		 Set of drifts	*722589041500
44	Install axial bearing (2d).
45	Install new Torlon rings (1a).	 Sleeve	*722589011400
46	Install radial bearing (11l).
	Install
47	Install clutch K2.		AR27.50-S-0612PS

Adjustment values of multi-disk clutch

Number	Designation				Transmission 722.9
BE27.51-N-1002-01C	Play in multiple-disc clutch K2	Contact force for clearance adjustment K2	M4	N	1200
		Number of internal plates	3	mm	1,70...2,10
			4	mm	1,90...2,30
			5	mm	2,10...2,50
			6	mm	2,20...2,60
			7	mm	–
			8	mm	–