Replacing Multiple Disc Clutches and Brakes
Replacing Multiple Disc Clutches and Brakes
- Disassemble transmission. Disassembling and Assembling Transmission
IMPORTANT!
- Check transfer plate for installation of a venting valve when repairing clutch A.
- If applicable, install a transfer plate with a venting valve.
Clutch A:
- Press Out input shaft (1) Check O ring (2), replacing if necessary.
- Compress clutch set and remove snap ring (3).
- Remove plate carrier (4)
- Lift Out plate set and diaphragm spring
- Note number of steel and lined plates
- Press Out clutch A piston with compressed air applied through bore.
Installation:
- Replace O-rings (5 and 6).
- Lubricate O-rings with light coat of ATF to make installation easier.
- Installed Order of Plates
- Insert noted number of removed steel and lined plates alternately, beginning with a spring and steel plate
1 Spring plates
2 Steel plates 1.8 mm
3 Lined plates
4 Plate carrier
- Place diaphragm spring in input shaft case with curved surface facing down
- Insert plate set with plate carrier
- Compress clutch set and insert snap ring
Clutch B:
- Remove snap ring (1).
- Remove steel and lined plates.
- Note number of steel and lined plates.
- Bend open lockplate (2).
- Press down on diaphragm spring with Special Tool 24 2 030 and remove snap ring (3).
Installation:
- Replace and lock lockplate.
- Insert diaphragm spring with curved surface facing up.
- Press out clutch B piston with compressed air applied through oil bore.
Installation:
- Check 0-rings (4 and 5), replacing if necessary.
- Lubricate 0.rings with a light coat of ATF to make installation easier.
Installed Order of Plates:
Insert noted number of removed steel and lined plates alternately, beginning with a steel plate.
1 Steel plates 1.8 mm (635 CSi = 2.1 mm)
2 Lined plates
3 End plate 4.5 mm
IMPORTANT!
Insert end plate with ground side facing lined plate.
4 Housing
Clutch C' and C:
To make this step easier, place complete set in a pipe with an inside diameter of 29 mm (1.142") and clamp in S vise.
- Remove Special Tool 24 0 040. Lift off centering plate (5).
Installation:
- Bevelled beads must engage in bevelled openings.
- Press down on diaphragm spring with Special Tool 242 030 and lift out split retaining ring (1).
Installation:
- Insert diaphragm spring with curved surface facing up.
- Press out clutch C' piston with compressed air applied through oil bore.
Installation:
- Check 0-rings (2 and 3), replacing if necessary.
- Lubricate 0-rings with light coat of ATF to make installation easier.
- Remove all steel and lined plates.
- Note number of steel and lined plates.
- Pull out one-way clutch (2)
- Press down diaphragm spring with Special Tool 24 2 030 and lift out split retaining ring (2).
Installation:
- Insert diaphragm spring with cursed surface facing up.
- Press out clutch C piston with compressed air applied through oil bore
Installation
- Check O-rings (3 and 4), replacing if necessary
- Lubricate O-rings with light coat of ATF to make installation easier.
- Install one way clutch
IMPORTANT!
- Bent over tabs or word "oben" must be seen.
C Installed Order:
Insert noted number of removed steel and lined plates alternately beginning with a steel plate
5 Steel plates 1.8 mm
IMPORTANT!
Steel plates for a BMW 635 CSi have different thickness (1.5 and 2.1 mm).
The thinner (1.5 mm) steel plate is installed on the piston end
6 Lined plates
7 End plate 4.5 mm
IMPORTANT!
- Insert end plate that center tooth of three teeth group engages in opening of cylinder.
C' Installed Order:
- Insert noted number of removed steel and lined plates alternately, beginning with a lined plate.
5 Steel plates 1.8 mm
IMPORTANT!
Steel plates for a BMW 635 CSi have different thicknesses (1.5 and 2.1 mm).
The thinner (1.5 mm) steel plate is installed on the piston end.
6 Lined plates
IMPORTANT!
- External splines of steel plates must not be plated in bevelled openings of cylinder.
Clutch D'.
Clutches C' and C removed.
- Lift clutch member with clutch D off of planet gear set,
- Remove snap ring (1).
- Remove steel and lined plates.
- Note number of steel and lined plates.
Press down on diaphragm spring with Special Tool 24 20 30 and lift out snap ring (2).
Installation:
- Insert diaphragm spring with curved surface facing up.
Press Out clutch D piston with compressed air applied through oil bore
Installation:
- Check O-rings (3 and 4), replacing if necessary
- Lubricate O-rings with a light coat of ATF to make installation easier.
- Place planet plate with one-way clutch on hub of cylinder D.
Installed Order of Plates:
Insert noted number of removed steel and lined plates alternately, beginning with a steel plate.
5 Steel plates 1.8 mm
6 Lined plates
7 End plate 1.2 mm
Disassemble planet gear set,
- Remove support ring (1).
Installation:
- Mount support ring with fins facing down
- Take off planet gear set (2).
- Pull out sun gear shaft (3).
- Remove axial bearing (4) and thrust washer (5).
- Lift Out snap ring (6).
- Remove hollow gear (7) and planes plate (8).
- Remove thrust washers (9), and axial bearing (10).
- Take off spacer (11).
- Lift Out snap ring (12).
- Take off hollow gear (13).
Clutches E and F:
- Remove sun gear (1) and planet carrier (2).
- Remove angled washer (3), axial bearing (4) and thrust washer (5).
Installation:
- Install angled washer (3) with collar facing planet carrier.
- Take off Special Tool 24 1 010.
- Lift cylinder F off of cylinder E.
- Lift off cylinder E on output shell,
- Take off thrust washer (6), axial bearing (7) and steel/copper angled washer (8).
Installation:
- Mount cylinder E and turn until it rests on stop.
Cylinder must rest on copper angled washer.
When holding output shaft it must now be possible to turn cylinder E clockwise.
It should lock in opposite direction.
Clutch F:
- Lift out snap ring (1).
- Remove plate set.
- Note number of steel and lined plates.
- Remove piston for clutch F
- Press down on diaphragm spring with Special Tool 24 2 020 and lift out split retaining ring (1).
Installation:
- Insert diaphragm spring with curved surface facing up.
- Press out piston for clutch F with two suitable mandrels.
Installation:
- Check O-rings (2 and 3), replacing if necessary
- Lubricate O-rings with a light coat of ATF to make installation easier
Installed Order of Plates.
- Insert nosed number of removed steel and lined plates alternately, beginning with a Steel plate
1 Steel plates 2.1mm
2 Lined plates
3 End plate 4.5mm
Clutch E.
- Lift out snap ring (1).
- Remove plate set.
- Note number of steel and lined plates.
- Remove piston for clutch E
- Press down on diaphragm spring with Special Tool 24 2 020 and remove the split retaining ring (2).
Installation
- Insert diaphragm spring with curved surface facing up
- Lift off thrust cover (3).
- Press out clutch E pistols with compressed air applied through air bore
Installation
- Check O-rings (4 and 5) replacing if necessary.
- Lubricate O-rings with a light coat of ATF to make installation easier.
Installed Order of Plates:
- Insert noted number of removed steel and lined plates alternately, beginning with a steel plate.
1 Steel plates 1.5 mm
2 Lined plates
3 End plate 4.5 mm
- Connect cylinders E and F by turning.
- Collar on output shaft must protrude by distance A = approx. 10 mm (0.394").
- Apply Special Tool 24 1 010.
Removing One-way Clutch:
- Lift out snap ring (1).
- Press out output shaft (2).
- Lift off carrier (3).
- Pull or press off one-way clutch.
- Press one-way clutch cage out of outer race carefully.
CAUTION
Needles could jump out of cage.
Installation:
- Place one-way clutch cage on the outer race and align.
- Press in oneway clutch cage against stop and then turn until metal edge engages in holding groove of outer race.
- Use plate carrier (3) to turn one-way clutch outer race clockwise and mount race on inner race.
Clearance between one-way clutch inner race and outer race should be at least 0.1mm (0.004")