2005 MERCEDES-BENZ SPRINTER Service Repair Manual

GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE
(1) The floor shifter lever and gate positions
should be in alignment with all transmission PARK,
NEUTRAL, and gear detent positions.
(2) Engine starts must be possible with floor shift
lever in PARK or NEUTRAL gate positions only.
Engine starts must not be possible in any other gear
position.
(3) With floor shift lever handle push-button not
depressed and lever in:
(a) PARK position - Apply forward force on cen-
ter of handle and remove pressure. Engine starts
must be possible.
(b) PARK position - Apply rearward force on cen-
ter of handle and remove pressure. Engine starts
must be possible.
(c) NEUTRAL position - Normal position. Engine
starts must be possible.
(d) NEUTRAL position - Engine running and
brakes applied, apply forward force on center of
shift handle. Transmission shall not be able to shift
from NEUTRAL to REVERSE.
REMOVAL
(1) Move selector lever to position9D9.
(2) Remove top (3) (Fig. 146) of the center section
of instrument panel.
(3) Remove bottom (2) (Fig. 147) of the center sec-
tion of instrument panel.
(4) Pry ball socket of transmission shift cable off
ball knob at the shift lever assembly (SLA). Use a
suitable slotted screwdriver.
(5) Raise and support vehicle.
(6) Detach shift cable at transmission.
(a) Unlatch ball socket latch (Fig. 148) of cable.
(b) Unclip shift cable retainer from retainer
bracket. When pulling out cable, press together
hooks of shift cable retainer at the points shown
(arrows).
(c) Pull shift cable out of ball socket. Ball socket
can remain on transmission lever.
(7) Remove the shift cable grommet from the dash
panel.
(8) Remove the shift cable from the vehicle.
INSTALLATION
(1) Pass the shift cable through the opening in the
dash panel and seat the shift cable grommet into the
hole.
(2) Install the shift cable (Fig. 149) to the trans-
mission.
Fig. 146 Remove Top Section Of Center Instrument
Panel
1 - SHIFT LEVER ASSEMBLY FRAME TRIM
2 - STORAGE COMPARTMENT
3 - TOP CENTER PART OF INSTRUMENT PANEL
4 - SCREW
5 - PLUG CONNECTIONS
6 - ASHTRAY
Fig. 147 Remove Bottom Section Of Center
Instrument Panel
1 - SCREW
2 - BOTTOM CENTER PART OF INSTRUMENT PANEL
VAAUTOMATIC TRANSMISSION - NAG1 21 - 109

(a) Push shift cable onto the transmission shift
lever ball socket.
(b) Latch ball socket latch of cable.
(c) Clip shift cable retainer into retainer bracket.
(3) Lower vehicle.
(4) Install the transmission shift cable onto the
ball knob at the SLA.
(5) Install the bottom section (2) (Fig. 150) of the
center section of instrument panel.
(6) Install the top section (3) (Fig. 151) of the cen-
ter section of instrument panel.
(7) Verify repair.
Fig. 148 Remove Shift Cable From Transmission
1 - SHIFT CABLE
2 - TRANSMISSION SHIFT LEVER
Fig. 149 Install Shift Cable Onto Transmission
1 - SHIFT CABLE
2 - TRANSMISSION SHIFT LEVER
Fig. 150 Install Bottom Section Of Center
Instrument Panel
1 - SCREW
2 - BOTTOM CENTER PART OF INSTRUMENT PANEL
Fig. 151 Install Top Section Of Center Instrument
Panel
1 - SHIFT LEVER ASSEMBLY FRAME TRIM
2 - STORAGE COMPARTMENT
3 - TOP CENTER PART OF INSTRUMENT PANEL
4 - SCREW
5 - PLUG CONNECTIONS
6 - ASHTRAY
21 - 110 AUTOMATIC TRANSMISSION - NAG1VA
GEARSHIFT CABLE (Continued)

HOLDING CLUTCHES
DESCRIPTION
Three multiple-disc holding clutches (Fig. 152), the
front, middle and rear multiple disc clutches B1, B3
and B2, are located in the planetary gear sets in the
transmission housing.A multiple-disc holding clutch consists of a number
of internally toothed discs (10) on an internally
toothed disc carrier and externally toothed discs (9)
on an externally toothed disc carrier, which is rigidly
connected to the transmission housing.
Fig. 152 Holding Clutches
1 - B1 CLUTCH 10 - CENTER PLANETARY GEARSET ANNULUS GEAR
2 - EXTERNALLY TOOTHED DISC 11 - CENTER PLANETARY GEARSET PINION GEARS
3 - INTERNALLY TOOTHED DISC 12 - CENTER PLANETARY GEARSET SUN GEAR
4 - B3 CLUTCH 13 - FRONT PLANETARY GEARSET PINION GEARS
5 - B2 CLUTCH 14 - FRONT PLANETARY GEARSET SUN GEAR
6 - B3 CLUTCH PISTON 15 - B1 CLUTCH INTERNALLY TOOTHED DISC CARRIER
7 - B2 CLUTCH PISTON 16 - B1 CLUTCH PISTON
8 - B2 CLUTCH INTERNALLY TOOTHED DISC CARRIER 17 - B1 CLUTCH EXTERNALLY TOOTHED DISC CARRIER
9 - REAR PLANETARY GEARSET PLANETARY CARRIER
VAAUTOMATIC TRANSMISSION - NAG1 21 - 111

OPERATION
The holding clutches (Fig. 153) connect the annu-
lus gear, sun gear, or planetary carrier of a planetary
gear set against the transmission housing in order to
transmit the drive torque.
If the piston (16) on multiple-disc holding clutch
B1 (1) is subjected to oil pressure, it presses the
internal (3) and external discs (2) of the disc set
together. The internally toothed disc carrier (15)
locks the sun gear (14) against the housing. The
planetary pinion gears (13) turn on the sun gear (14).
If the multiple-disc holding clutch B2 (5) is actu-
ated via the piston (7), the piston compresses the disc
set. The internally toothed disc carrier (8) locks the
sun gear (12) against the housing. The planetary pin-
ion gears (11) turn on the sun gear (12).
If the multiple-disc holding clutch B3 (4) is actu-
ated via the piston (6), the planetary carrier (9) andthe annulus gear (10) are locked. When the multiple-
disc brake B3 (4) is actuated, the direction of rotation
is reversed.
HOLDING CLUTCH B1
DISASSEMBLY
(1) Remove snap-ring (7) (Fig. 154).
(2) Remove multiple-disc pack (6) and disc spring
(5) from outer multiple-disc carrier.
(3) Place the Multi-use Spring Compressor 8900
(8) (Fig. 154) on disc spring (3) and compress the
spring until the snap-ring (4) is exposed.
(4) Remove snap-ring (4).
(5) Remove piston (2) from the outer multiple-disc
carrier by carefully blowing compressed air into the
bore (A).
Fig. 153 Holding Clutches
1 - B1 CLUTCH 10 - CENTER PLANETARY GEARSET ANNULUS GEAR
2 - EXTERNALLY TOOTHED DISC 11 - CENTER PLANETARY GEARSET PINION GEARS
3 - INTERNALLY TOOTHED DISC 12 - CENTER PLANETARY GEARSET SUN GEAR
4 - B3 CLUTCH 13 - FRONT PLANETARY GEARSET PINION GEARS
5 - B2 CLUTCH 14 - FRONT PLANETARY GEARSET SUN GEAR
6 - B3 CLUTCH PISTON 15 - B1 CLUTCH INTERNALLY TOOTHED DISC CARRIER
7 - B2 CLUTCH PISTON 16 - B1 CLUTCH PISTON
8 - B2 CLUTCH INTERNALLY TOOTHED DISC CARRIER 17 - B1 CLUTCH EXTERNALLY TOOTHED DISC CARRIER
9 - REAR PLANETARY GEARSET PLANETARY CARRIER
21 - 112 AUTOMATIC TRANSMISSION - NAG1VA
HOLDING CLUTCHES (Continued)

ASSEMBLY
(1) Install piston (2) (Fig. 155) in outer multiple-
disc carrier (1). Press in piston using the disc spring
(3) and Multi-use Spring Compressor 8900 (8). Place
compressor (8) on disc spring (3) and compress until
the groove of the snap-ring is exposed
NOTE: Check vulcanized gasket, replace if neces-
sary.
(2) Insert snap-ring (4) (Fig. 155).
NOTE: The collar of the snap-ring must point
towards the multiple-disc pack. After installing,
check snap-ring for correct seat.
(3) Insert disc spring (5) and multiple-disc pack (6)
in the outer multiple-disc carrier.
(4) Insert snap-ring (7).NOTE: Pay attention to sequence of discs. Place
new friction multiple-discs in ATF fluid for one hour
before installing.
(5) Measure B1 clutch clearance.
(a) Mount Pressing Tool 8901 (1) (Fig. 156) on
outer multiple disc.
(b) Using a lever press (Fig. 156), 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. 157) at three points between the snap-ring (6)
and outer multiple-disc (4). During the measure-
ment, the snap-ring (6) must contact the upper
bearing surface of the groove in the outer multiple-
disc carrier (5). The correct clearance is 2.3-2.7 mm
(0.091-0.106 in.) for 2 friction disc versions, 2.7-3.1
mm (0.106-0.122 in.) for 3 disc versions, and
3.0-3.4 mm (0.118-0.134 in.) for 4 disc versions.
Fig. 154 Holding Clutch B1
1 - HOLDING CLUTCH B1 OUTER CARRIER 5 - DISC SPRING
2 - PISTON 6 - MULTIPLE DISC PACK
3 - DISC SPRING 7 - SNAP-RING
4 - SNAP-RING 8 - MULTI-USE SPRING COMPRESSOR 8900
VAAUTOMATIC TRANSMISSION - NAG1 21 - 113
HOLDING CLUTCH B1 (Continued)

(d) Adjust with snap-ring (6), 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.).
Fig. 155 Holding Clutch B1
1 - HOLDING CLUTCH B1 OUTER CARRIER 5 - DISC SPRING
2 - PISTON 6 - MULTIPLE DISC PACK
3 - DISC SPRING 7 - SNAP-RING
4 - SNAP-RING 8 - MULTI-USE SPRING COMPRESSOR 8900
Fig. 156 Measure B1 Clutch Clearance
1 - PRESSING TOOL 8901
2 - B1 CLUTCH OUTER CARRIER
21 - 114 AUTOMATIC TRANSMISSION - NAG1VA
HOLDING CLUTCH B1 (Continued)

HOLDING CLUTCH B2
DISASSEMBLY
(1) Remove snap ring (1) (Fig. 158).
(2) Take multiple-disc pack B2 (2) and disc spring
(3) out of the outer multiple-disc carrier B2 (8). The
outer multiple-disc carrier for the multi-disc holding
clutch B2 is the piston for the multiple-disc holding
clutch B3 at the same time.
(3) Place the Multi-use Spring Compressor 8900 on
the spring disc (14) and compress the spring until
the groove for the snap-ring is exposed.
(4) Remove snap-ring (16) (Fig. 158).
(5) Remove spring plate (15) and disc spring (14).
(6) Separate piston guide ring (13) and the B2 pis-
ton (10) from the B3 piston (8) by blowing com-
pressed air into the bore (D) (Fig. 159).
(7) Press piston guide ring (13) out of the B2 pis-
ton (10).
Fig. 157 B1 Clutch Stack-up
1 - DISC SPRING
2 - OUTER MULTIPLE DISC - 1.8 mm (0.071 IN.)
3 - OUTER MULTIPLE DISC - 2.8 mm (0.110 IN.)
4 - OUTER MULTIPLE DISC - 4.0 mm (0.158 IN.)
5 - B1 OUTER CARRIER
6 - SNAP-RING
7 - FRICTION DISCS
8 - PISTON
Fig. 158 Holding Clutch B2
1 - SNAP-RING 9 - B3 PISTON SEALING RING
2 - MULTIPLE DISC PACK 10 - B2 PISTON
3 - DISC SPRING 11 - PISTON GUIDE SEALING RING
4 - B2 AND B3 PISTON GUIDE 12 - PISTON GUIDE SEALING RING
5 - O-RING 13 - PISTON GUIDE RING
6 - B3 PISTON SEALING RING 14 - PISTON BACK PRESSURE DISC SPRING
7 - B3 PISTON SEALING RING 15 - SPRING PLATE
8 - B3 PISTON/B2 OUTER DISC CARRIER 16 - SNAP-RING
VAAUTOMATIC TRANSMISSION - NAG1 21 - 115
HOLDING CLUTCH B2 (Continued)

(8) Separate piston guide (4) from the B3 piston
(8) by blowing compressed air into the bore (A) (Fig.
159).
ASSEMBLY
(1) Assemble piston guide (4) (Fig. 160) and B3
piston (8) in the correct position.
(2) Check all sealing rings (Fig. 161), replace if
necessary. The rounded off edges on the sealing rings
(6), (3), and (2) must point outwards. The rounded off
edges on the sealing ring (4) must point inwards.
(3) Insert B2 piston (10) (Fig. 160) in B3 piston (8).
(4) Insert piston guide ring (2) (Fig. 162). The
valve (1) in the piston guide ring must be on top.
(5) Insert disc spring (14) (Fig. 160) and spring
plate (15). Insert disc spring with the curvature
towards the spring plate(6) Place Multi-use Spring Compressor 8900 on the
disc spring (14) and compress the spring until the
groove for the snap-ring is exposed.
(7) Insert snap-ring (16).
NOTE: Pay attention to sequence of discs. Place
new friction multiple-discs in ATF fluid for one hour
before installing.
(8) Insert disc spring (3) and multiple-disc pack (2)
in the B2 outer multiple-disc carrier.
(9) Insert snap-ring (1).
NOTE: During the measurement the snap-ring (8)
must contact the upper bearing surface of the
groove in the outer multiple-disc carrier.
(10) Measure the B2 clutch pack clearance.
(a) Mount Pressing Tool 8901 (1) (Fig. 163) on
outer multiple disc.
(b) Using a lever press, compress the 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. 164) at three points between the snap-ring (8)
and outer multiple-disc (7).
(d) The correct clutch clearance is 1.9-2.3 mm
(0.075-0.091 in.) for the four friction disc versions
and 2.0-2.4 mm (0.079-0.095 in.) for the five disc
versions.
(e) Adjust with snap-ring (8), if necessary. Snap-
rings are available in thicknesses of 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.).
Fig. 159 B2 Clutch Oil Supply Locations
A - B3 PISTON
B - B2 PISTON GUIDE RING SIDE
C - K3 CLUTCH FEED
D - B2 PISTON SHIFT SIDE
21 - 116 AUTOMATIC TRANSMISSION - NAG1VA
HOLDING CLUTCH B2 (Continued)