52. 1-2-3-4-5-6 Clutch Piston Housing Assemble

1-2-3-4-5-6 Clutch Piston Housing Assemble

Special Tools
* J 24204-2 - Bar and Stud Assembly
* J 36850 - Transjel(R) Lubricant
* J 44525 - Clutch Backing Plate Selector
* J 47339-1 - Piston Return Spring Compressor
* J 47339-2 - Seal Area Protector

For equivalent regional tools, refer to Special Tools (Allison - Automatic Transmission).




1. Install the piston seal rings (1, 2) onto the 4-5-6 clutch piston (3).
2. Lubricate the 4-5-6 clutch piston ID and OD seal rings (1, 2) with J 36850 - lubricant.




3. Position the 1-2-3-4, 4-5-6 clutch housing (2) on the work table so that the rear of the housing is facing up.
4. Install the O-ring (1) into the bottom groove on the inner hub of the 1-2-3-4, 4-5-6 clutch housing (2).




5. Position the 4-5-6 clutch piston (1) so that the rear of the piston is facing up.
6. Install the 4-5-6 clutch piston (1) into the 1-2-3-4, 4-5-6 clutch housing (2).
7. Make sure the 4-5-6 clutch piston (1) is seated on the 1-2-3-4, 4-5-6 clutch housing (2).




8. Install the seal ring (1) onto the 1-2-3-4 clutch piston housing (2).
9. Lubricate the 1-2-3-4 clutch piston housing seal (1) with J 36850 - lubricant.




10. Align the 4-5-6 clutch piston return spring assembly (2) so that the notches of the spring assemblies are facing and aligned with the tangs of the 4-5-6 clutch piston (4).
11. Install the 4-5-6 clutch piston return spring assembly (2) into the 4-5-6 clutch piston (4).
12. Align the 1-2-3-4 clutch piston housing (1) so that the rear of the housing is facing up.
13. Install the 1-2-3-4 clutch piston housing (1) into the 4-5-6 clutch piston (4).




14. Position the 1-2-3-4, 4-5-6 clutch housing (8) on the base of J 24204-2 - assembly (10) so that the rear of the housing is facing up.
15. Install J 47339-2 - protector (7) onto the shaft of J 24204-2 - assembly with the bowl down.
16. Install the retaining ring (6) onto the surface of J 47339-2 - protector (7).
17. Install the spring (5) of J 47339-2 - protector onto the shaft of J 24204-2 - assembly.
18. Install J 47339-1 - compressorJ 47339-1 - compressor (4) onto the shaft of J 24204-2 - assembly.
19. Install the J 24204-2 - assembly ball bearing (3) and washer (2) onto the shaft of J 24204-2 - assembly.
20. Install the J 24204-2 - assembly wing nut (1) onto the shaft of J 24204-2 - assembly.
21. Compress the 4-5-6 clutch piston return spring assembly until the retaining ring groove on the inner hub of the 1-2-3-4, 4-5-6 clutch housing (8) is visible.
22. Install the retaining ring (6) into the 1-2-3-4, 4-5-6 clutch housing inner hub.
23. Make sure the retaining ring (6) is seated all around the clutch housing (8).
24. Remove all J tools.




25. Install the 1-2-3-4 clutch piston ID seal ring (1) and the 1-2-3-4 clutch piston OD seal ring (2) onto the 1-2-3-4 clutch piston (3).
26. Lubricate the seal rings with J 36850 - lubricant.




27. Position the 1-2-3-4, 4-5-6 clutch housing (4) on the work table so that the rear of the housing is facing up.
28. Align the 1-2-3-4 clutch piston (3) so that the spring indents are facing up.
29. Install the 1-2-3-4 clutch piston (3) into the 1-2-3-4 clutch piston housing (4).
30. Make sure the 1-2-3-4 clutch piston (3) is seated in the 1-2-3-4 clutch piston housing (4).
31. Align the 1-2-3-4 clutch piston return spring assembly (2) so that the springs are facing and aligned with the spring pockets of 1-2-3-4 clutch piston (3).
32. Install the 1-2-3-4 clutch piston return spring assembly (2) into the 1-2-3-4 clutch piston (3).
33. Lubricate the 1-2-3-4 clutch balance piston ID and OD seal area with J 36850 - lubricant.
34. Align the 1-2-3-4 clutch balance piston (1) and position so that the rubber seal is facing down.




35. Position the 1-2-3-4, 4-5-6 clutch housing (6) on the base of J 24204-2 - assembly (7) so that the rear of the housing is facing up.
36. Install J 47339-1 - compressor (4) onto the shaft of J 24204-2 - assembly (7).
37. Center J 47339-1 - compressor (4) on the 1-2-3-4 clutch balance piston.
38. Install the J 24204-2 - assembly ball bearing (3) and washer (2) onto the shaft of J 24204-2 - assembly.
39. Install the J 24204-2 - assembly wing nut (1) on the shaft of J 24204-2 - assembly.
40. Compress the 1-2-3-4 clutch piston return spring assembly until the retaining ring groove on the 1-2-3-4 clutch housing is visible.
41. Install the retaining ring (5) into the 1-2-3-4 clutch housing.
42. Remove all of the J tools.




43. Install 2 overlap seal rings (4) onto the turbine shaft (3).
44. Position the turbine shaft (3) on the work table so that the rear of the shaft is facing up.
45. Align the 1-2-3-4, 4-5-6 clutch housing (2) with the rear of the turbine shaft (3) so that the rear of the clutch housing is facing up.
46. Install the 1-2-3-4, 4-5-6 clutch housing (2) onto the rear of turbine shaft (3).
47. Install the retaining ring (1) onto the turbine shaft (3).
48. Make sure the retaining ring (1) is seated completely around the turbine shaft (3).




49. Starting with a 1-2-3-4 clutch steel plate, alternately install seven 1-2-3-4 clutch steel plates (2) and seven 1-2-3-4 clutch fiber plates (1) onto the turbine shaft (3).





Note: Special tools J 44525-4 selector tool (4) and J 44525-5 pressure plate (3) are silver plated for easy identification. Do not use the pressure plate and selector tool from the J 44525 - selector set if they are not matched in color.

50. Align J 44525-5 pressure plate (3) with the turbine shaft so that the countersunk holes of J 44525-5 pressure plate (3) are facing up.
51. Install J 44525-5 pressure plate (3) onto the turbine shaft.
52. Align J 44525-1 compressor (2) with the turbine shaft so that the inner ridge of J 44525-1 compressor (2) is facing down.
53. Slide the inner ridge of J 44525-1 compressor (2) into the turbine shaft retaining ring groove.
54. Align the holes in J 44525-1 compressor (2) with the countersunk holes of J 44525-5 pressure plate (3).
55. Hand install 2 bolts (1) of J 44525 - selector into the holes of J 44525-1 compressor (2). Tighten the bolts to 1.8 Nm (16 lb in).





Note: The shift quality of the transmission depends heavily upon selecting the correct 1-2-3-4 clutch backing plate.

56. Perform the following procedure for each tab of J 44525-4 selector tool (1):

1. Place the flat surface, tabbed end of J 44525-4 selector tool (1) onto the top surface of J 44525-5 pressure plate (2).
Note: At most, 2 of the different tabs will fit into the retaining ring groove.

2. Try to slide the tabbed end of J 44525-4 selector tool (1) into the retaining ring groove on the turbine shaft.
3. If a tab fits into the retaining ring groove, record the 4-digit ID number located on the tab of J 44525-4 selector tool (1). Refer to Selective Components Specifications (Selective Components Specifications) to determine the correct backing plate.

57. Select a 1-2-3-4 clutch backing plate as follows:

* If no tab of J 44525-4 selector tool (1) fits into the retaining ring groove, select the 1-2-3-4 clutch backing plate with ID No. 2420.
* If one or more tabs of J 44525-4 selector tool (1) fit into the retaining ring groove, select the 1-2-3-4 clutch backing plate with an ID No. corresponding to the highest number recorded in the previous step.

58. Remove J 44525 - selector from the turbine shaft.




59. Align the selected 1-2-3-4 clutch backing plate (3) so that the beveled edge of the backing plate is facing up.
60. Install the 1-2-3-4 clutch backing plate (3) onto the turbine shaft (4).
61. Install the retaining ring (2) onto the turbine shaft (4).
62. Lift the 1-2-3-4 clutch backing plate (3) and install the spiral retaining ring (1) into the 1-2-3-4 clutch backing plate (3).





Caution: Installing the thrust bearing assembly onto the rear of the turbine shaft in the wrong direction may cause permanent damage to the transmission. The blue stripe must be visible.

63. Align thrust bearing assembly (2) so that the blue stripe on the thrust bearing assembly is facing away from turbine shaft (3).
64. Install the thrust bearing assembly (2) into the turbine shaft (3).
65. Make sure the blue stripe on the thrust bearing assembly is visible.
66. Center the 1-2-3-4 clutch plates (4).
67. Install the 1-2-3-4 clutch drive hub (1) over the 1-2-3-4 clutch plates (4).
68. Make sure the 1-2-3-4 clutch drive hub (1) has seated on the thrust bearing assembly (2).





Caution: Installing the thrust bearing assembly onto the rear of the 1-2-3-4 drive hub in the wrong direction may cause permanent damage to the transmission. The blue stripe must be visible.

69. Align the thrust bearing assembly (2) so that the blue stripe on the thrust bearing assembly is facing away from the 1-2-3-4 clutch drive hub (3).
70. Install the thrust bearing assembly (2) onto the rear of the 1-2-3-4 clutch drive hub (3).
71. Make sure the blue stripe on the thrust bearing assembly is visible.
72. Align the 4-5-6 clutch drive hub (1) so that the smaller end is facing up.
73. Install the 4-5-6 clutch drive hub (1).




74. Starting with a 4-5-6 clutch steel plate, alternately install seven 4-5-6 clutch steel plates (2) and six 4-5-6 clutch fiber plates (1) into the 1-2-3-4, 4-5-6 clutch housing.




75. Align the tangs of the bronze thrust washer (1) with the holes in the 4-5-6 clutch drive hub (2).
76. Install the bronze thrust washer (1) onto the 4-5-6 clutch drive hub (2).




77. Align the input sun gear (3) so that the gear teeth of the sun gear face the concave face of the input sun gear flange (2).
78. Install the input sun gear (3) into the input sun gear flange (2).
79. Make sure the splines are engaged.
80. Hold the sun gear and align the double wide splines of the input sun gear flange (2) with the double wide spaces on the 1-2-3-4, 4-5-6 clutch housing (4).
81. Install the input sun gear (3) with the input sun gear flange (2) into the 1-2-3-4, 4-5-6 clutch housing (4).
82. Install the input sun gear external retaining ring (1) into the 1-2-3-4, 4-5-6 clutch housing (4).
83. Make sure the retaining ring is seated all the way around the 1-2-3-4, 4-5-6 clutch housing.
84. Remove tools J 24204-2 - assembly and J 43777 .