Direct/Coast Clutch, Reaction Carrier Disassemble

Direct/Coast Clutch, Reaction Carrier Disassemble

Tools Required

* J 23327 Clutch Spring Compressor
* J 41232 Direct Clutch Return Spring
* J 41236 Coast Cutch Return Spring Compressor




1. Remove the selective thrust bearing (103) and the thrust washer (104) from the input shaft of the direct and coast clutch assembly (105).




2. Remove the input sun gear to input sun gear shaft snap ring (534).
3. Remove the input sun gear (533) from the input sun gear shaft (511).
4. Remove the thrust bearing (532) from the reaction carrier assembly (531).




5. Remove the reaction carrier assembly (531). You will find a thrust bearing permanently installed in the reaction carrier assembly under the pinion gears.
6. Remove the reaction sun gear and shell assembly (529).
7. Remove the thrust bearing (527) from the reaction carrier shaft and shell assembly (526).




8. Remove the reaction carrier shaft and shell assembly (526).
9. Remove the thrust bearing (524) from the top of the sprag race assembly.




10. Remove the clutch retaining snap ring (517).
11. Remove the direct clutch plates from the direct coast clutch input housing. The direct clutch consists of a backing plate (523), steel plates (521) and fiber plates (522).




12. Lift up on the input sun shaft (511) in order to remove the input sun shaft (511) and the sprag (512) as an assembly.
13. Remove the inner race to input housing thrust bearing (510) if the inner race to input housing thrust bearing did not remain with the input sun shaft and sprag assembly.




14. Remove the coast clutch plates from the input housing (502). The coast clutch consists of four steel plates (508) and four fiber plates (509).




15. Compress the direct clutch return spring assembly. Use the J 41232 and J 23327 or equivalent.
16. Remove the spring retaining snap ring (520).
17. Remove the J 41232 and J 23327.




18. Remove the direct clutch return spring (519).
19. Remove the direct clutch piston and seal assembly (518).




20. Compress the coast clutch return spring. Use the J 41236 and J 23327 or equivalent.
21. Remove the spring retaining snap ring (507).
22. Remove the J 41236 and J 23327.




23. Remove the coast clutch return spring retainer (506) and the release spring (505).
24. Remove the coast clutch piston and seal assembly (504).




25. Remove and discard the 4 Teflon(TM) oil seals (500) from the input shaft assembly (502).




26. Remove the input sprag assembly (512 and 514-516) from the input sun gear shaft (511).
27. Remove the snap ring (516) from the sprag assembly (515).
28. Remove the sprag clutch assembly (515) from the sprag outer race (512).
29. Remove the 2 end bearings (514) from the sprag clutch assembly (515).





Important: The pistons are reusable if not damaged. If the pistons or seals are damaged, replace the assembly.

30. Inspect the piston (518 and 504) and seal assemblies for damage or cut seals.
31. Inspect the clutch spring assemblies (519 and 505) for distortion or missing springs.




32. Inspect the direct clutch and coast clutch retainer and ball assemblies for leaks or damage.
33. Inspect the oil passages for blockage.
34. Inspect the bushings and bearings for excessive wear.
35. Inspect the seal grooves on the input shaft for nicks or damage.
36. Inspect the splines, housings and clutch plates for cracks, excessive wear or damage.
37. Inspect all other components for damage or excessive wear.