Service Information

Document Title: Function Group: Information Type: Date:

Clutch K2, reconditioning 421 Service Information 20/10/2015
Profile:
PT2519 PID:22419

Clutch K2, reconditioning

Op nbr

Total procedure time (hr): NaN

Tools:
9993736 Press tool
11667001 Handle
11667060 Drift plate
88800055 Guide

Figure 1
Clutch K2
1 Retainer ring 6 Outer seal ring 11 Lock ring
2 Spring retainer 7 Bushing 12 Clutch drum
3 Spring 8 Clutch housing 13 Steel disc
4 Brake piston 9 Bushing 14 Friction disc
5 Inner seal ring 10 Lock ring 15 Thrust plate

For position and designation of the transmission's included parts, see Transmission, component position
Dismantling

1. Place the clutch on a flat surface.

Weight: approx. 14 kg (30.9 lbs)

2. Pry out one end of the upper lock ring with a scribe, screwdriver, or similar. Hold the lock ring in place by pressing
up the thrust plate with a screwdriver.

Figure 2

3. Pry out the end of the lock ring and pull it out with pliers.

4. Remove the thrust plate.

Figure 3

1. Thrust plate
5. Remove the plates.
NOTE!
Remove the discs as a unit so that they are not mixed up. In case of reinstallation, install the discs in the order that
they were removed.

Figure 4

1. Plates

6. Press down the spring retainer with 9993736 Press tool.

Figure 5

1. 9993736 Press tool

7. Disassemble the snap ring.

 Figure 6

8. Let up on the workshop press and remove 9993736 Press tool.

9. Remove the spring retainer and thrust springs.

Figure 7

1. Spring retainer
2. Thrust springs

10. Locate and pry out the opening in lock ring that holds the thrust plate. Use a scribe, screwdriver, or similar. Remove
the lock ring between the clutch housing and clutch drum.
 Figure 8

1. Clutch drum
2. Clutch housing

11. Part the clutch drum and the clutch housing.

12. Mark up the drain hole's position in the brake piston in relation to the clutch housing.

Figure 9

1. Drain hole in brake piston

2. Clutch housing
3. Marking

13. Remove the piston from the clutch housing. Pry it up with two screwdrivers or similar.
 Figure 10

14. Inspection

 Check that the discs are not worn unevenly or abnormally, burnt (discoloured), or are damaged in any
other way. If so, change all discs in the clutch.
 Check that the thrust springs are correct, visual check.
 Clean and check the parts for damage and wear. Change damaged and worn parts as needed.

15. Remove the bushing in the end of the cylinder on the clutch housing. Use a suitable puller.

Figure 11

16. Install a new bushing in the cylinder end on the clutch housing. Use 11667001 Handle and 11667060 Drift plate
 Figure 12

1. 11667001 Handle
2. 11667060 Drift plate

17. Drive in the bushing 18 ±0.5 mm (0.71 ±0.020 in) under the edge of the clutch housing's shaft, see figure.

Figure 13
Clutch housing for clutch K2

18. Remove the bushing in the end of the shaft on the clutch housing. Use a suitable puller.
 Figure 14

19. Install a new bushing in the shaft end of the clutch housing. Use 11667001 Handle and 11667060 Drift plate.

Figure 15

1. 11667001 Handle
2. 11667060 Drift plate

20. Drive in the bushing 3.5 ±0.5 mm (0.14 ±0.020 in) under the edge of the clutch housing's shaft, see figure.
 Figure 16
Clutch housing for clutch K2

21. Install new seal rings in the piston. The groove in the piston shall face the pressure side on the piston, as shown in
the figure.

Figure 17

1. Inner seal ring

2. Outer seal ring

 Figure 18
P shows pressure side

1. Inner seal ring

2. Outer seal ring

22. Lubricate the seal rings on the piston with vaseline.

Figure 19

23. Install the piston in the clutch drum according to earlier marking.
 Figure 20

1. Drain hole in brake piston

2. Clutch housing
3. Marking

24. Assemble the clutch drum and the clutch housing.

Install a new lock ring.
NOTE!
Push in the lock ring so much that the opening on the lock ring ends up 1/4–1/2 turn in the drum.

Figure 21

1. Clutch drum
2. Clutch housing

25. Place the clutch in a workshop press.

 Figure 22

1. Thrust spring
2. Spring retainer

26. Install the thrust springs and spring retainer.

NOTE!
Centre the thrust springs carefully in the spring retainer. Centre the thrust springs with a screwdriver.

27. Press down the spring retainer with 9993736 Press tool.
Install the retainer ring.
NOTE!
Check that the springs are centred in the spring retainer and that the retaining ring is installed correctly in its
groove.

Figure 23

1. 9993736 Press tool

2. Retainer ring

28. Let up with the workshop press and remove 9993736 Press tool.
29. Install 88800055 Guide in the clutch drum.
NOTE!
Leave 88800055 Guide in the clutch until it is reinstalled in the transmission.

Figure 24

1. 88800055 Guide

30. Install the discs (5 steel discs and 5 friction discs). Begin with a steel disc, then alternate between friction discs and
steel discs.
NOTE!
When reinstalling the old discs, install in the same order as they were removed.

Figure 25

1. Plates

31. Fit the thrust plate without lock ring.

 Figure 26

1. Thrust plate

Checking disc clearance

32. Press down the pressure plate as far as possible and lift the clutch drum.
Measure the distance (h1) between the pressure plate and the edge of the clutch drum.
Note the measurement (h1)!

Figure 27

33. Install a new lock ring. Let 10–20 mm (0.4–0.8 in) of the lock ring protrude.
 Figure 28

1. Lock ring

34. Press up the pressure plate against the lock ring with a screwdriver, and measure the distance between the pressure
plate and the ring gear (h2).
NOTE!
Measure at the same points as dimension h1 was measured before.

Note the measurement (h2)!

Figure 29

35. Calculate disc clearance (s) by subtracting measurement h2 from h1, that is:
s = h1 – h2, where

s = disc clearance
h1 = distance between edge of the clutch drum and pressure plate, without lock ring for pressure plate
installed
h2 = distance between edge of the clutch drum and pressure plate, with lock ring for pressure plate
installed

Example:
 Measured distance for h1 = 3.5 mm (0.14 in)
Measured distance for h2 = 1,4 mm (0.06 in)
s = 3.5–1.4 = 2.1 mm (s = 0.138–0.055 = 0.083 in) which is within specifications for permitted disc clearance.

Permitted disc clearance, see Hydraulic transmission, specifications

36. If the disc clearance is outside specifications, adjust it with steel discs. For dimensions of steel discs, see the Parts
Catalog.

37. Slide in the lock ring in the groove in the clutch drum. Push in the lock ring so much that the opening on the lock
ring ends up 1/4–1/2 turn in the drum.

Figure 30

1. Lock ring