Mercedes

Transcription

1 96 Mercedes Clutch K - Brake Band B - Disc Brake B - Wide Planet Pinion 5 - One-Way Clutch F 6 - Clutch K 7 - Brake Band B 8 - Narrow Planet Pinion Int. Band Fwd. Band Rev. Clutch Direct Clutch th Clutch OWC Speed B B B K K F Reduction X (X) X.68 X X. X X. X X R X (X) X 5. (X) K bridges the one-way clutch during deceleration (coasting). Reference Chart: B/Intermediate B/Forward B/Reverse K/Direct K/th F/Low One Way Clutch

2 Line Pressure PSI in Idle Stall in Drive Governor Pressure: /-/ of Road Speed Governor Pressure Should be Approx. 5-0 PSI Vacuum control unit version "B" has been installed up to February 98. Starting February 98 the vacuum control unit with the thrust pin for heat expansion compensation version "A" is installed. Update to the late version on overhaul A - Working Line pressure M - Modulating Pressure R - Governor Pressure - Vacuum Control Unit Modulator Pressure: Adjusted W/ a gauge no vacuum, in specified MPH use supplied chart for proper modulator usage & pressures. 7. Models MPH Version Color PSI.0 Green 5.0 Green.0 Red 5.09 Red.0 Red 57. White 8. Red 5. Red 58.5 Green.7 Black 6.0 Black 57. Black 6. Red 58. Green 5. Black Black 55.5 Black 58.5 Red 55.5 Black Black Black Red 55.6 Red Models MPH Version Color PSI.00 Green 6.0 Green.08 Green Red 8.0 Green 5. Red 7. Brown.6 Black.8 Red* 7* To serial #868 Black* 7** From Serial #869

3 Governor Assembly 7. Governor Assembly Secondary Pump. Lock Ring. Bearing Ring. Cover 5. Governor 5 B Clutch Clearance Measurement "A" Position Gauge Bar on Case Surface. Measure Distance to Edge of B Plate Spring. (D) Measurement "A" Detail D Measurement "B" Position Gauge Bar on B Piston. (E) Measure Distance to Installed Gasket "A" - "B" = "C" "C" =.5 -.0mm /.059" -.079" C Gauge Bar E Measurement "A" Measurement "B"

4 Measurement "F" Detail Measurement "H" Detail A B C G A. Washer B. Shim C. Bearing K to Pump Clearance Measurement "B" (Previous Page) Position Gauge Bar on B Piston. Measure Distance to Installed Gasket. Measurement "F" Position Gauge Bar on Case Surface. Measure Distance to K Thrust Surface Measurement "G" Add K Shim, Thrust Bearing & Washer Thickness' Together "B" - "F" - "G" = "H" "H" = mm /.06" -.0" W/Rear Housing Installed Version "A" Thrust bearing B together with brake band guide without oil discharge hole (arrow). Installed up to transmission serial No Version "B" Thrust Bearing B with oil discharge hole down the way (arrow) only in combination with brake band guide with additional oil discharge hole (arrow). Installed effective Transmission serial No Version "C" Thrust bearing B with enlarged stroke, identified by elimination of annular groove (arrow) in combination with brake band piston B with reduced contact stroke. Consequently, size "a" is.6-.8mm; was.-.6 mm. Installed effective Transmission serial No Note: Install thrust bearing B with enlarged stroke only together with the modified brake band piston B.

5 D C A B A. B Brake Servo B. B Brake Band C. B Brake Band D. B Brake Servo B Brake Band Adjustment. Fig. Install Servo Cover & Ring Press band toward band piston - direction of arrow so that piston contacts cover. (Fig. ) Measure dimension "A" on brake band Press band toward thrust element - in direction of arrow until it bottoms (Fig. ) A Measure dimension "B" on brake band Measured A - B = C. C = Brake band travel mm /.7" -.6" Fig. A B Note: Thrust pins (A) are available with lengths of 7.; 8.8 and 9.6 mm for brake band B.858",.9" &.95" 5

6 A 5 B Brake Band Piston. Piston Seal, Lip Type. Thrust Pin. Adjustment Shims. O-Ring 5. Piston, B B A: Servo Adjustment Shims Not to Exceed 6.5mm /.56" B: Servo Assembly/Disassembly Tool, Mercedes # or Equivalent Tool Has a Bolt Thread Pitch of mm /.00" One Turn = A Distance of mm /.00" Delayed Engagement in all Forward Ranges May be Due to the "T" Type B Brake Piston Seal The "T" Type Seal is not as Flexible and May Not Seal Well Against the Servo Bore. By Grinding a 0 Degree Champher Around the Outer Land on the Piston - See Illustration B Brake Band Travel.8 -.5mm /.07" -.098" ( Turns of the Bolt to Achieve Nm /.5 Ft. Lb) This Will Allow Additional Oil Pressure to Directly Affect the Piston Seal During the Apply Mario Aristides Independent Transmission 6

7 / K Assembly 0 6 7/8 5 K Assembly Replacing K & K Aluminum Support O-Ring In Mercedes 7. And 7. Read Complete Instructions Carefully And Completely Before Replacing O-Ring. K Aluminum Support O-Ring Replacement. Remove three rivets from the drum holding the support to the drum.. Drill the holes in the aluminum to /6".. Counter sink the area on the inside of the support where the head of the bolt meets the support. The head of the bolt needs to be recessed in the support so that the bolt doesn't interfere with the piston travel.. Tap the three holes in the drum with a 0- machine tap and clean all parts thoroughly. 5. Place the new O-Ring in the support groove using assembly lube to hold the O-Ring in place. 6. Install support into drum, install the three bolts being sure to pull down the support evenly, torque bolts to 6 inch pounds. 7. Turn the drum over and remove excess part of the bolt that is sticking out. K Aluminum Support O-Ring Replacement. Do steps and from above.. The K drum support is a different design than the K. You need to use a /" counter sink drill bit so the support has the same counter as the bolts. The head of the bolts will not interfere with piston operation.. Grind off the edge of the bolt heads so that they clear the support and fit down in the pockets.. Do steps -7 from above. 7

8 ,00 K & K Adjust the release clearance to 0.7-.mm One.0 Rubber Ball Here Place Spring Under This Ball (8).5 Steel Check Ball Locations Manual Valve. Strainer. Shift Valve K. Check Valve 5. Check Ball w/spring 6. Check Ball 7. Check Valve 8. Restrictor Valve K 9. Lubricating Pressure Shaft 0. Check Valve w/restrictor * * Not Used in 7. Models 7 9. Pressure Limiting Valve. Modulating Pressure Relief Valve. Lubricating Pressure Valve 8

9 . Throttle Check Valve. Plate Type Check Valve. Check Valve with Strainer. Throttle Check Valve with Strainer - Orifice.0 5. Throttle Check Valve - Orifice.0. K Shut Off Valve. Primary Pump Check Valve. Lubricating Pressure Shift Pin. Reverse Gear Shut Off Plunger. Secondary Pump Shift Valve. Screens. Check Valve 9

10 Upper Valve Body (Top View) Upper Valve Body (Bottom View). Manual Valve. Converter Adaption Control Valve. - Plunger Command Valve. - Command Valve 5. - Command Valve 6. - Command Valve Sleeve 7. - Plunger Command Valve 8. Shift Valve Bridging Clutch Plug 9. B Shift Valve 0. Kickdown Shift Valve. Governor Pressure Shift Valve. Pressure Control Valve. Pressure Control Valve Plunger. - Command Valve. - Command Valve Plunger. B Shift Valve. Basic Pressure Control Valve 5. Working Pressure Control Valve 6. Full Throttle Control Valve 7. B Plunger Control Valve 8. B Control Valve 9. Governor Pressure Boost Valve The 7. has two plates early & late. The early plate will not fit the late valve body, however, the late model plate will fit the early model valve body. 7. Early Regular Case to V.B Plate Shown Case to Valve Plate 0

11 Lower Valve Body (Front View) Lower Valve Body (Back View). Accumulator Kick Down. RV Shut Off Valve. Brake Circuit Shut Off Valve. B Accumulator Control Valve 5. Deceleration Control Valve 6. B Accumulator 7. K Accumulator Control Valve 8. K Accumulator. Shift Control Pressure Valve. K Accumulator. K Accumulator Control Valve. Accumulator Switching On 5. RV Shut Off Valve 6. Accumulator Switching On Control Valve 7. K Shift Valve 8. B Detent Valve A complaint of harsh reverse after overhaul may be due to the reverse feed restrictor into the wrong passage. Install the tapered end in first.

12 Lower Valve Body Update There are three versions of the K shift valve body. We have illustrated these in the illustration below. Line-up "A" is the second and most common version. The "C" is the first version. The "B" line-up was first found in the 7. and became the third in the late model 7.. "E" shift control pressure valves can be found to be installed valve first (early) or spring than valve (late). Be sure to check valve type and line-up.. Shift control Pressure Valve. K Accumulator. K Accumulator Control Valve. Accumulator Switching On 5. RV Shut Off Valve 6. Accumulator Switching On Control Valve 7. K Shift Valve 8. B Detent Valve If water should mix with the transmission fluid. Then this complete valve line-up must be replaced. This line-up is comprised of all plastic parts. NOTE: This condition causes a complaint of no passing gear (kick-down) poor transmission performance and no kick-down to first gear. REMEMBER this transmission has normal second gear starts. Mercedes Up TV Plunger Assembly The TV valve line-up is different in the Mercedes models 0 SEL, 560 SEL and SL models. This change was made in the 986 model year. Figure illustrates the valve line-up. Drawing by Wayne Colonna ATSG Copyright 99 SOME OF THE INFORMATION IN THIS BOOKLET MAY HAVE BEEN PROVIDED OR APPROVED BY THE AUTOMATIC TRANSMISSION SERVICE GROUP AND/OR THE AUTOMATIC TRANSMISSION REBUILDERS ASSOCIATION. THE INFOR- MATION CONTAINED HEREIN IS ACCURATE TO THE BEST OF OUR KNOWLEDGE. WE ARE NOT RESPONSIBLE FOR ANY INACCURACIES OR WARRANTY CLAIMS WHICH MAY RESULT FROM THE USE OF THIS INFORMATION.