2005 MERCEDES-BENZ SPRINTER Service Repair Manual

TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt, B2 Clutch Carrier 16 - 141
Bolt, B1 Carrier to
Converter Housing10 - 88.5
Nut, Propeller Flange 120 88.5 -
Bolt, Electrohydraulic Unit 8 - 71
Bolt, Transmission
Housing to Converter
Housing20 - 177
Bolts, Oil Pan 8 - 71
Screws, Valve Body/
Housing Side Cover4-35
Bolt, Shift Plate 8 - 71
Bolt, Solenoid Leaf Spring 8 - 71
Plug, Oil Pan Drain 20 - 177
Nut, Shifter Mechanism to
Floor Pan7-65
SPECIAL TOOLS - NAG1 AUTOMATIC
TRANSMISSION
SPECIAL TOOL CROSS REFERENCE CHART
MB
TOOL #MILLER
TOOL #DESCRIPTION
N/A C-3339 DIAL INDICATOR SET
N/A C-4171 DRIVE HANDLE
N/A 6311 GAUGE BAR
N/A 8266 END-PLAY SET
N/A 8266-18 END-PLAY ADAPTER
N/A 8863A DIPSTICK
140 586
13 43 008900 MULTI-USE SPRING
COMPRESSOR
208 589
00 21
00N/A8901 PRESSING TOOL
N/A 8902A SEAL INSTALLER
N/A 9078 STAKING TOOL
N/A 9082 BEARING REMOVER
N/A 9287 BEARING INSTALLER
VAAUTOMATIC TRANSMISSION - NAG1 21 - 69
AUTOMATIC TRANSMISSION - NAG1 (Continued)

Dial Indicator - C-3339
Handle, Universal - C-4171
Bar, Gauge - 6311
End Play Set - 8266
Adapter, Geartrain End-play - 8266-18
Dipstick - 8863A
Compressor, Multi-use Spring - 8900
21 - 70 AUTOMATIC TRANSMISSION - NAG1VA
AUTOMATIC TRANSMISSION - NAG1 (Continued)

Tool, Pressing - 8901
Installer, Seal - 8902A
Tool, Staking - 9078
Remover, Bearing - 9082
Installer, Bearing - 9287
VAAUTOMATIC TRANSMISSION - NAG1 21 - 71
AUTOMATIC TRANSMISSION - NAG1 (Continued)

DRIVING CLUTCHES
DESCRIPTION
Three multi-plate driving clutches (Fig. 73), the
front, middle and rear multi-plate clutches K1, K2
and K3, are located in the planetary gear sets in the
transmission housing.
A multi-plate driving clutch consists of a number of
internally toothed discs (4) on an internally toothed
disc carrier and externally toothed discs (3) on an
externally toothed disc carrier.
OPERATION
The driving clutches (Fig. 74) produce a non-posi-
tive locking connection between two elements of a
planetary gear set or between one element from each
of two planetary gear sets in order to transmit the
drive torque.
If the piston (20) on multi-plate clutch K1 (1) is
subjected to oil pressure, it presses the internal and
external discs of the disc set together. The sun gear
(17) is locked with the planetary carrier (15) via the
externally toothed disc carrier (19) and the internally
toothed disc carrier (18). The front planetary gear set
is thus locked and turns as a closed unit.
Fig. 73 Driving Clutches
1 - K1 CLUTCH 12 - CENTER PLANETARY GEARSET SUN GEAR
2 - K2 CLUTCH 13 - K2 CLUTCH EXTERNALLY TOOTHED DISC CARRIER
3 - EXTERNALLY TOOTHED DISC 14 - K2 CLUTCH PISTON
4 - INTERNALLY TOOTHED DISC 15 - FRONT PLANETARY GEARSET PLANETARY CARRIER
5 - K3 CLUTCH 16 - FRONT PLANETARY GEARSET ANNULUS GEAR
6 - K3 CLUTCH EXTERNALLY TOOTHED DISC CARRIER 17 - FRONT PLANETARY GEARSET SUN GEAR
7 - K3 CLUTCH PISTON 18 - K1 CLUTCH INTERNALLY TOOTHED DISC CARRIER
8 - K3 CLUTCH INTERNALLY TOOTHED DISC CARRIER 19 - K1 CLUTCH EXTERNALLY TOOTHED DISC CARRIER
9 - REAR PLANETARY GEARSET SUN GEAR 20 - K1 CLUTCH PISTON
10 - CENTER PLANETARY GEARSET PLANETARY CARRIER 21 - DRIVE SHAFT
11 - CENTER PLANETARY GEARSET ANNULUS GEAR
21 - 72 AUTOMATIC TRANSMISSION - NAG1VA

If the multi-plate clutch K2 (2) is actuated via the
piston (14), the piston compresses the disc set. The
annulus gear (16) of the front planetary gear set is
locked with the annulus gear (11) of the center plan-
etary gear set via the externally toothed disc carrier
(13) and the center planetary carrier (10) on which
the internally toothed discs are seated. Annulus gear
(16) and annulus gear (11) turn at the same speed as
the input shaft (21)If the multi-plate clutch K3 (5) is actuated via the
piston (7), the piston compresses the disc set. The
sun gear (12) of the center planetary gear set is
locked with the sun gear (9) of the rear planetary
gear set via the externally toothed disc carrier (6)
and the internally toothed disc carrier (8). Sun gear
(12) and sun gear (9) turn at the same speed.
Fig. 74 Driving Clutches
1 - K1 CLUTCH 12 - CENTER PLANETARY GEARSET SUN GEAR
2 - K2 CLUTCH 13 - K2 CLUTCH EXTERNALLY TOOTHED DISC CARRIER
3 - EXTERNALLY TOOTHED DISC 14 - K2 CLUTCH PISTON
4 - INTERNALLY TOOTHED DISC 15 - FRONT PLANETARY GEARSET PLANETARY CARRIER
5 - K3 CLUTCH 16 - FRONT PLANETARY GEARSET ANNULUS GEAR
6 - K3 CLUTCH EXTERNALLY TOOTHED DISC CARRIER 17 - FRONT PLANETARY GEARSET SUN GEAR
7 - K3 CLUTCH PISTON 18 - K1 CLUTCH INTERNALLY TOOTHED DISC CARRIER
8 - K3 CLUTCH INTERNALLY TOOTHED DISC CARRIER 19 - K1 CLUTCH EXTERNALLY TOOTHED DISC CARRIER
9 - REAR PLANETARY GEARSET SUN GEAR 20 - K1 CLUTCH PISTON
10 - CENTER PLANETARY GEARSET PLANETARY CARRIER 21 - DRIVE SHAFT
11 - CENTER PLANETARY GEARSET ANNULUS GEAR
VAAUTOMATIC TRANSMISSION - NAG1 21 - 73
DRIVING CLUTCHES (Continued)

DRIVING CLUTCH K1
DISASSEMBLY
(1) Remove snap-ring (11) (Fig. 75) from outer
multiple-disc carrier (6).
(2) Take multiple-disc pack (12) out of outer mul-
tiple-disc carrier (6).(3) Place Multi-use Spring Compressor 8900 on the
spring plate (8) and compress the spring until the
snap-ring (10) is exposed.
(4) Remove snap-ring (10) (Fig. 75).
(5) Take out disc spring (7) and remove piston (6)
by carefully blowing compressed air into the bore (A).
(6) Remove snap-ring (3) and take out front free-
wheeling clutch F1 (2).
Fig. 75 Driving Clutch K1 Components
1 - K1 OUTER DISC CARRIER 7 - DISC SPRING
2 - FREEWHEELING CLUTCH F1 8 - SPRING PLATE
3 - SNAP-RING 9 - SPRING PLATE SEALING RING
4 - OUTER DISC CARRIER SEALING RING 10 - SNAP-RING
5 - PISTON SEALING RING 11 - SNAP-RING
6 - PISTON 12 - MULTIPLE DISC PACK
21 - 74 AUTOMATIC TRANSMISSION - NAG1VA

ASSEMBLY
(1) Install piston (6) (Fig. 76) in the outer multi-
ple-disc carrier (1). Check sealing rings (4 and 5),
replace if necessary. The rounded off edges of the
sealing rings must point outwards.
(2) Insert disc spring (7) (Fig. 76). Insert disc
spring with the curvature towards the piston.
(3) Insert spring plate (8). Insert spring plate with
the curvature towards the sun gear. Check sealing
ring (9), replace if necessary.
(4) Place Multi-use Spring Compressor 8900 on
spring plate (8) and compress the spring until the
groove of the snap-ring is exposed.(5) Insert snap-ring (10) (Fig. 76). After installing,
check snap-ring for correct seat
NOTE: Pay attention to sequence of discs. Place
new friction multiple-discs in ATF fluid for one hour
before installing.
(6) Insert multiple-disc pack (12) in the outer mul-
tiple-disc carrier.
(7) Insert snap-ring (11).
(8) Measure the K1 clutch pack clearance.
Fig. 76 Driving Clutch K1 Components
1 - K1 OUTER DISC CARRIER 7 - DISC SPRING
2 - FREEWHEELING CLUTCH F1 8 - SPRING PLATE
3 - SNAP-RING 9 - SPRING PLATE SEALING RING
4 - OUTER DISC CARRIER SEALING RING 10 - SNAP-RING
5 - PISTON SEALING RING 11 - SNAP-RING
6 - PISTON 12 - MULTIPLE DISC PACK
VAAUTOMATIC TRANSMISSION - NAG1 21 - 75
DRIVING CLUTCH K1 (Continued)

(a) Mount Pressing Tool 8901 (1) (Fig. 77) on
outer multiple disc.
(b) Using a lever press, compress pressing tool
as far as the stop (then the marking ring is still
visible, see small arrow).
(c) Using a feeler gauge, determine the play9L9
(Fig. 78) at three points between the snap-ring (5)
and outer multiple-disc (3).
(d) During the measurement the snap-ring (5)
must contact the upper bearing surface of the
groove in the outer multiple-disc carrier.
(e) The correct clutch clearance is 2.7-3.1 mm
(0.106-0.122 in.) for three friction disc versions,
3.0-3.4 mm (0.118-0.134 in.) for four disc versions,
3.3-3.7 mm (0.130-0.146 in.) for five disc versions,
and 3.6-4.0 mm (0.142-0.158 in.) for six disc ver-
sions.
(f) Adjust with snap-ring (5), if necessary. Snap-
rings are available in thicknesses of 2.6 mm (0.102
in.), 2.9 mm (0.114 in.), 3.2 mm (0.126 in.), 3.5 mm
(0.138 in.), 3.8 mm (0.150 in.), and 4.1 mm (0.162
in.).
(9) Insert front freewheeling clutch F1 (2) and fit
snap-ring (3). The freewheeling clutch F1 (2) must be
installed in the direction of the arrow.
DRIVING CLUTCH K2
DISASSEMBLY
(1) Remove snap-ring (15) from the K1 inner mul-
tiple-disc carrier with integrated front gear set (1)
and take off hollow gear (14).
(2) Remove drive shaft with clutch K2 (3) (Fig. 79).
(3) Remove needle thrust bearing (2).
(4) Remove snap-ring (13) (Fig. 79) from K2 outer
multiple-disc carrier.
(5) Take out multiple-disc pack (12).
(6) Take out disk spring (11) (Fig. 79).
(7) Fit Multi-use Spring Compressor 8900 (Fig. 80)
onto spring retainer (9) and press until snap-ring
(10) is released.
(8) Remove snap-ring (10) (Fig. 79).
(9) Take out disc spring (7) and pull piston (6) out
of outer multiple-disc carrier.
Fig. 77 Measure K1 Clutch Clearance
1 - PRESSING TOOL 8901
2 - K1 OUTER DISC CARRIER
Fig. 78 Driving Clutch K1 Stack-up
1 - OUTER MULTIPLE DISC - 1.8MM (0.071 IN.)
2 - OUTER MULTIPLE DISC - 2.8MM (0.110 IN.)
3 - OUTER MULTIPLE DISC - 4.0MM (0.158 IN.)
4 - K1 OUTER DISC CARRIER
5 - SNAP-RING
6 - FRICTION DISCS
7 - DISC SPRING
8 - PISTON
21 - 76 AUTOMATIC TRANSMISSION - NAG1VA
DRIVING CLUTCH K1 (Continued)