K2 Clutch - Assembly

ASSEMBLY

Special Tools:









Input Clutch K2 Components





1. Install piston (9) in outer multiple-disc carrier. Inspect seals (6 and 7), replace if necessary. The rounded edges of the inner piston seal (7) must point to the outside.
2. Insert disk spring (10) and spring retainer (12). Insert disk spring (10) with curved side pointing toward spring retainer (12). Inspect seal (11), replace if necessary.










3. Place Multi-use Spring Compressor (1) on spring plate and press until the groove (2) of the snap-ring is exposed.
4. Insert snap-ring.

5. Insert disk spring (14).

NOTE: Pay attention to the sequence of discs. If the original clutch discs are reused, be sure to return the disc identified on disassembly as belonging on top of the disc spring (14) to its original location.

6. Insert multiple-disk set (16) into outer multiple-disk carrier.
7. Fit snap-ring (17).










8. Measure K2 clutch clearance by mounting Pressing Tool (1) on outer multiple disc.
9. Using a lever press, compress pressing tool to the upper most line marked 1200 N (the marking ring is still visible, see small arrow).










10. Using a feeler gauge, determine the play "L" at three points between the snap-ring (6) and outer multiple-disc (4).
11. During the measurement the snap-ring (6) must contact the upper bearing surface of the groove in the outer multiple-disc carrier.
12. The correct clutch clearance is 2.3-2.7 mm (0.091-0.106 in.) for three friction disc versions, 2.4-2.8 mm (0.095-0.110 in.) for four disc versions, 2.5-2.9 mm (0.099-0.114 in.) for five disc versions, and 2.7-3.1 mm (0.106-0.122 in.) for six disc versions.
13. Adjust with snap-ring (6), if necessary. Snap-rings are available in thicknesses of 2.3 mm (0.091 in.), 2.6 mm (0.102 in.), 2.9 mm (0.114 in.), 3.2 mm (0.126 in.), 3.5 mm (0.138 in.), and 3.8 mm (0.150 in.).




Input Clutch K2 Components





14. Insert axial needle bearing (3) into K1 inner multiple-disk carrier. Insert axial needle bearing (3) with a little grease to prevent it slipping.
15. Install input shaft in K1 inner multiple-disc carrier with integrated front gear set (2).










NOTE: Insure that the Hollow Gear (18) is oriented during installation such it protrudes from the K2 Retainer.

16. Fit internally-geared wheel (18) and install snap-ring.