Overdrive clutch with planetary gear fastening element (Opel Frontera B)

Removal

Remove the gear wheel (2) from the planetary gear mounting element.



Remove the needle bearing from the planetary gear.

Clamp the overdrive clutch in a vice with the planetary gear mounting element (1) mounted on the shaft.

Warning: Cover the jaws of the vice with soft metal.

Using special tool KM-396 (4), remove the retaining ring (3) from the shaft.

Material copied from this portal: OPELBOOK.ru



Remove the overdrive clutch with the planetary gear retainer (1) from the shaft (2).



Check the condition of the shaft sealing rings and remove the rings by moving them apart in the direction of the arrows.





Install new sealing rings on the shaft and lubricate them with transmission oil.

Remove the planetary gear retainer (1) from the overdrive clutch (2).



Remove the sun gear (3) from the planetary gear retainer (1).

Use a screwdriver to remove the retaining ring (4) from the overdrive clutch.

Remove the clutch discs and plates from the overdrive drum.

Warning: When reusing clutch discs and plates, install them in their original locations.

Using the special device KM-679 (2), compress the spring washer so that the retaining ring moves freely in the groove, then using the special tool KM-396 (1), remove the retaining ring.



Remove the overdrive clutch assembly from the clutch sleeve.

Remove the roller assembly (5) from the cams (6) of the overdrive clutch rollers.

Warning! Do not lose the spring (3) and cylindrical rollers (4).

Remove the overdrive clutch spring seat (1).

Remove the steel plates (2).



Remove the piston (3) from the clutch drum.

Installation

Check the overdrive clutch, piston and planetary gear components for wear or damage.

Using a metal feeler gauge, check the lateral clearance between the gears and the planetary gear fastener, which should be within 0.24-0.64 mm.



Install the piston, piston shell and inner seal, after lubricating them with lubricant.

Install the KM-687-1 -A bushing (1) into the piston and the KM-687-2 bushing (2) onto the clutch drum bushing, which will provide protection for the working edges of the seal.



Install the clutch piston (3) into the clutch drum (4) and remove the KM-687 bushings.

Install the spring on the clutch piston (7) and the Belleville spring washer (6).

Install the spring plate (5) into the clutch housing.



Install the roller assembly onto the cams, then install the overdrive clutch assembly onto the clutch sleeve.





Using the special tool KM-679 (2), compress the Belleville spring washer so that the retaining ring can be installed in the groove, then using the special tool KM-396 (1), install the retaining ring.



Install the clutch discs and plates in the reverse order of removal.



Install the pressure plate (3) so that the UP mark is at the top.



Install the retaining ring (4).

Install the sun gear (1) onto the splines of the clutch sleeve (2) and use a screwdriver to align the protrusions of the clutch discs.



Install the planetary gear retainer (3) into the clutch drum and then onto the sun gear, rotating the planetary gear retainer clockwise until it is properly seated, without applying force.

After assembly, rotate the roller assembly to ensure it functions properly.

Place the thrust washer on the planetary gear wheel (3) with the machined side of the washer facing upwards.



Install the shaft (1) into the overdrive clutch assembly with the planetary gear and secure with the retaining ring (2), using the KM-396 device to correctly install the ring.

Install the planetary gear wheel (3) onto the planetary gear retainer.