2006 MERCEDES-BENZ SPRINTER Service Manual

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Page 1841 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (7) Fit Multi-use Spring Compressor 8900 (1) (Fig.
89) onto spring retainer (12) and press until snap-
ring (2) is released.
(8) Remove snap-ring (2) (Fig. 88).
(9) Take out disc spring (10) and pull

Page 1842 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual ASSEMBLY
(1) Install piston (9) (Fig. 90) in outer multiple-
disc carrier. Inspect seals (6 and 7), replace if neces-
sary. The rounded edges of the inner piston seal (7)
must point to the outside.
(2

Page 1843 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (3) Place Multi-use Spring Compressor 8900 (1)
(Fig. 91) 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 attent

Page 1844 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (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.)

Page 1845 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual INPUT CLUTCH K3
DISASSEMBLY
(1) Remove snap-ring (1) (Fig. 94) from outer mul-
tiple-disc carrier.
(2) Remove multiple-disc pack (2) and disk spring
(3) from outer multiple-disc carrier. Note which
cl

Page 1846 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual ASSEMBLY
(1) Install piston (6) (Fig. 95) in the outer multi-
ple-disc carrier (8). Check sealing ring (7), replace if
necessary. The rounded off edges of the sealing ring
must point outwards.
(2) Ins

Page 1847 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (7) Measure the K3 clutch clearance by mounting
Pressing Tool 8901 (1) (Fig. 96) on outer multiple
disc.
(8) Using a lever press, compress pressing tool as
far as the stop (then the marking ring is st

(7) Measure the K3 clutch clearance by mounting
Pressing Tool 8901 (1) (Fig. 96) on outer multiple
disc.
(8) Using a lever press, compress pressing tool as
far as the stop (then the marking ring is still visible,
see small arrow).
(9) For transmissions using double sided friction
discs, use a feeler gauge to determine the play ªLº(Fig. 97) at three points between the snap-ring (8)
and outer multiple-disc (2).
(10) During the measurement the snap-ring (8)
must contact the upper bearing surface of the groove
in the outer multiple-disc carrier.
(11) The correct clutch clearance for transmissions
with double sided friction discs 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, and 2.5-2.9
mm (0.099-0.114 in.) for five disc versions.
(12) Adjust with snap-ring (8), if necessary. Snap-
rings are available in thicknesses of 2.0 mm (0.079
in.), 2.3 mm (0.091 in.), 2.6 mm (0.102 in.), 2.9 mm
(0.114 in.), 3.2 mm (0.126 in.), and 3.5 mm (0.138
in.).
(13) For transmissions using single sided friction
discs, use a feeler gauge to determine the play ªLº
(Fig. 98) at three points between the snap-ring (7)
and outer multiple-disc (2).
(14) During the measurement the snap-ring (7)
must contact the upper bearing surface of the groove
in the outer multiple-disc carrier.
(15) The correct clutch clearance for transmissions
with single sided friction discs is 2.3-2.7 mm (0.091-
0.106 in.) for six friction disc versions, 2.4-2.8 mm
(0.095-0.110 in.) for eight disc versions, and 2.5-2.9
mm (0.099-0.114 in.) for ten disc versions.
(16) Adjust with snap-ring (7), if necessary. Snap-
rings are available in thicknesses of 2.0 mm (0.079
in.), 2.3 mm (0.091 in.), 2.6 mm (0.102 in.), 2.9 mm
Fig. 96 Measure K3 Clutch Clearance
1 - PRESSING TOOL 8901
2 - OUTER DISC CARRIER
Fig. 97 Input Clutch K3 Stack-up - Double Sided
Discs
1 - OUTER DISC CARRIER
2 - OUTER MULTIPLE DISC - 4.0 MM (0.158 IN.)
3 - OUTER MULTIPLE DISC - 2.8 MM (0.110 IN.)
4 - OUTER MULTIPLE DISC - 1.8 MM (0.079 IN.)
5 - DISC SPRING
6 - PISTON
7 - FRICTION DISCS - 2.1 MM (0.083 IN.)
8 - SNAP-RING
Fig. 98 Input Clutch K3 Stack-up - Single Sided
Discs
1 - OUTER DISC CARRIER
2 - OUTER MULTIPLE DISC - 4.0 MM (0.158 IN.)
3 - OUTER MULTIPLE DISCS
4 - DISC SPRING
5 - PISTON
6 - INNER MULTIPLE DISCS
7 - SNAP-RING
21 - 104 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

Page 1848 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (0.114 in.), 3.2 mm (0.126 in.), and 3.5 mm (0.138
in.).
ELECTROHYDRAULIC UNIT
DESCRIPTION
The electrohydraulic control unit (Fig. 99) com-
prises the shift plate (13) made from light alloy for
the hy

(0.114 in.), 3.2 mm (0.126 in.), and 3.5 mm (0.138
in.).
ELECTROHYDRAULIC UNIT
DESCRIPTION
The electrohydraulic control unit (Fig. 99) com-
prises the shift plate (13) made from light alloy for
the hydraulic control and an electrical control unit
(12). The electrical control unit (12) comprises of a
supporting body made of plastic, into which the elec-
trical components (1 - 11) are assembled. The sup-
porting body is mounted on the shift plate (13) and
screwed to it.
Strip conductors inserted into the supporting body
make the connection between the electrical compo-
nents and a plug connector. The connection to the
wiring harness on the vehicle and the transmission
control module (TCM) is produced via this 13-pin
plug connector with a bayonet lock.
ELECTRICAL CONTROL UNIT
The electric valve control unit (7) (Fig. 100) con-
sists of a plastic shell which houses the RPM sensors
(1,12), regulating solenoid valves (3, 4), solenoid
valves (5, 6, 10), the TCC solenoid valve (11), the
park/neutral contact (9), and the transmission oil
temperature sensor (8). Conductor tracks integrated
into the shell connect the electric components to a
plug connection (2). This 13-pin plug connection (2)
establishes the connection to the vehicle-side cable
harness and to the transmission control module
(TCM). With the exception of the solenoid valves, all
other electric components are fixed to the conductor
tracks.
HYDRAULIC CONTROL UNIT
Working Pressure (Line Pressure or Operating Pressure)
(p-A)
The working pressure provides the pressure supply
to the hydraulic control and the transmission shift
elements. It is the highest hydraulic pressure in the
entire hydraulic system. The working pressure is reg-
ulated at the working pressure regulating valve in
Fig. 99 Electrical Unit Components
1 - SOLENOID CAP
2 - SOLENOID CAP
3 - BOLT - M6X32
4 - BOLT - M6X30
5 - LEAF SPRING
6 - MODULATING PRESSURE REGULATING SOLENOID VALVE
7 - SHIFT PRESSURE REGULATING SOLENOID
8 - 3-4 SHIFT SOLENOID
9 - TORQUE CONVERTER LOCK-UP SOLENOID
10 - 1-2/4-5 SHIFT SOLENOID
11 - 2-3 SHIFT SOLENOID
12 - ELECTRICHYDRAULIC CONTROL MODULE
13 - SHIFT PLATE
Fig. 100 Electrical Control Unit
1 - N3 SPEED SENSOR
2 - PLUG CONNECTOR
3 - MODULATING PRESSURE REGULATING SOLENOID
4 - SHIFT PRESSURE REGULATING SOLENOID
5 - 1-2/4-5 SHIFT SOLENOID
6 - 3-4 SHIFT SOLENOID
7 - ELECTRICAL CONTROL UNIT
8 - TRANSMISSION TEMPERATURE SENSOR
9 - STARTER INTERLOCK CONTACT
10 - 2-3 SHIFT SOLENOID
11 - TORQUE CONVERTER LOCK-UP SOLENOID
12 - N2 SPEED SENSOR
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 105

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