94 E320 transmission rebuild

[J. M. van Swaay]

1994 E320 (722.369 transmission)
240,000 miles
original transmission
no reverse
forward gears normal
no transmission leaks


I've been reading lots of transmission posts and rebuild manuals recently, but I have some specific questions that I really haven't found the answers to so here goes.

As usual, I'm already in way over my head, but this approach seems to facilitate lots of learning.

I've included a picture of the part that applies the clamping force to the B3 clutch pack. Note the scoring caused by intereference with the K1 clutch. The B3 friction bands are paper thin, this is obviously what allowed the B3 piston enough travel to cause the impact with the K1 clutch.

So, question 1: Does this kind of damage a require a full rebuild to insure no metal in the system? My guess is yes, but I'd like to hear from the experts.

Next, question 2: In order to remove the K2 clutch for rebuilding, must the small end of the transmission be disassembled, thereby allowing the gearset to be pulled out of the large end?

Finally, question 4: Just how much of a rebuild do the experts recommend? I'd like to be able to get 75,000 to 100,000 miles out of the rebuild.....

Thanks.

J. M. van Swaay