Input Clutch Assembly
INPUT CLUTCH ASSEMBLYDISASSEMBLY
1. Mount input clutch assembly (3) to Input Clutch Pressure Fixture Tool 8391.
2. Tap down reverse clutch reaction plate (4) to release pressure from snap ring (2).
3. Remove reverse clutch snap ring (3).
4. Pry up and remove reverse clutch reaction plate (1).
5. Remove reverse clutch pack (3,4). Tag components for assembly identification.
6. Remove the OD/Reverse pressure plate snap ring (1).
7. Remove OD/Reverse pressure plate (2).
8. Remove OD/Reverse pressure plate wave snap ring (3).
9. Remove OD clutch pack (4,5). Tag components for assembly identification.
10. Remove and inspect OD (1) and UD Shafts (4), as well as #3 thrust washer and plate (2, 3), and #2 needle bearing (5).
11. Remove the OD/UD reaction plate tapered snap ring (1), clutch plate (5), and first clutch disc (3).
12. Remove the UD clutch flat snap ring (4) and rest of the input clutch assembly (6). Tag clutch pack for assembly identification.
CAUTION: Compress return spring just enough to remove or install snap ring.
13. Using compressor 5059A (4) and an arbor press (2), compress UD clutch piston/spring enough to remove snap ring (3).
14. Refer to the exploded view as necessary when performing the following steps
15. Remove spring retainer (2), spring (3), and UD clutch piston (4).
16. Remove input hub tapered snap ring (2).
17. Tap on input hub with soft faced hammer (2) and separate input hub from OD/Reverse piston and clutch retainer.
18. Separate clutch retainer (2) from OD/Reverse piston (1).
19. Using Disk 6057 (4) and an arbor press (1), compress return OD/Reverse piston return spring just enough to remove snap ring (3).
20. Remove input shaft to input clutch hub snap ring (3).
21. Using a suitably sized socket (2) and an arbor press (1), remove input shaft (5) from input shaft hub (7).
22. Refer to the exploded view as necessary when performing the above steps
ASSEMBLY
Use petrolatum on all seals to ease assembly of components.
1. Using an arbor press (2), install input shaft (1) to input shaft hub (3).
2. Install input shaft snap ring (3).
3. Place OD/Reverse piston (1)return spring (2) and snap ring (3) into position.
4. Using an arbor press (1)and Disk 6057 (4), install OD/Reverse piston (5) return spring (6) and snap ring (3).
5. Install the OD/Reverse piston assembly (1) to the input clutch retainer (2).
6. Install the input hub/shaft assy. (rotate to align splines) (1) to the OD/Reverse piston/clutch retainer assy. (2).
7. Refer to the exploded view as necessary when performing the following steps.
8. Install input hub tapered snap ring (tapered side up with tabs in cavity) (2).
9. Install UD clutch piston (1).
10. Install UD piston return spring (1) and Installer 5067 (2).
11. Refer to the exploded view as necessary when performing the following steps.
12. Place the UD spring retainer (1) and snap ring (2) into position.
13. Using Compressor 5059A (6) and an arbor press (1), Install the UD spring retainer and snap ring (3) Compress just enough to install snap ring (3).
CAUTION: Compress return spring just enough to install snap ring.
14. Install the UD clutch pack (1,3). Leave out upper disc (2), until snap ring is installed.
15. Install the UD clutch flat snap ring (1).
16. Install the last UD clutch disc (1).
17. Place the OD/UD clutch reaction plate (1) and snap ring into position. The OD/UD clutches reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up.
18. Install the snap ring (1) using a screwdriver (2).
NOTE: Snap ring ends must be located within one finger of the input clutch hub. Be sure that snap ring is fully seated, by pushing with screwdriver, into snap ring groove all the way around.
19. Refer to the exploded view as necessary when performing the following steps.
20. Seat tapered snap ring (1) to ensure proper installation.
21. Install input clutch assembly (1) to the Input Clutch Pressure Fixture 8391 (2).
22. Set up dial indicator (1) on the UD clutch pack (2).
23. Using moderate pressure, press down and hold (near indicator) the UD clutch pack (2) with screwdriver or suitable tool and zero dial indicator. When releasing pressure on clutch pack, indicator reading should advance 0.005 - 0.010.
CAUTION: Do not apply more than 30 psi (206 kPa) to the underdrive clutch pack.
24. Apply 30 psi (206 kPa) to the underdrive hose on Input Clutch Pressure Fixture 8391 and measure UD clutch clearance. Measure and record UD clutch pack measurement in four (4) places, 90° apart.
25. Take average of four measurements and compare with UD clutch pack (2) clearance specification. Underdrive clutch pack clearance must be 0.94 - 1.50 mm (0.037 - 0.059 inch).
26. If necessary, select the proper reaction plate to achieve specifications:
UNDERDRIVE REACTION PLATE THICKNESS:
27. Install the OD clutch pack (four frictions/three steels) (1).
28. Install OD pressure plate waved snap ring (1).
29. Install the OD/Reverse pressure plate (1) with large step down (towards OD clutch pack) (2).
30. Refer to the exploded view as necessary when performing the following steps.
31. Install OD pressure plate flat snap ring (3).
32. Measure OD clutch pack clearance. Set up dial indicator (1) on top of the OD/Reverse pressure plate.
33. Zero dial indicator and apply 30 psi (206 kPa) air pressure to the overdrive clutch hose on Tool 8391. Measure and record OD clutch pack measurement in four (4) places, 90° apart.
34. Take average of four measurements and compare with OD clutch pack clearance specification. The overdrive (OD) clutch pack clearance is 1.07 - 3.25 mm (0.042 - 0.128 inch).
If not within specifications, the clutch is not assembled properly. There is no adjustment for the OD clutch clearance.
35. Install reverse clutch pack (two frictions/one steel) (1,2).
36. Install reverse clutch reaction plate with the flat side down towards reverse clutch.
37. Refer to the exploded view as necessary when performing the following steps.
38. Tap reaction plate (3) down to allow installation of the reverse clutch snap ring (1) Install reverse clutch snap ring (1).
39. Pry up reverse reaction plate (4) to seat against snap ring (2).
40. Set up a dial indicator (1) on the reverse clutch pack (2).
REVERSE CLUTCH SNAP RING THICKNESS:
41. Using moderate pressure, press down and hold (near indicator) reverse clutch disc (2) with screwdriver or suitable tool and zero dial indicator (1). When releasing pressure, indicator should advance 0.005 - 0.010. as clutch pack relaxes.
42. Apply 30 psi (206 kPa) air pressure to the reverse clutch hose on Input Clutch Pressure Fixture 8391. Measure and record reverse clutch pack measurement in four (4) places, 90° apart.
43. Take average of four measurements and compare with reverse clutch pack clearance specification. The reverse clutch pack clearance is 0.89 - 1.37 mm (0.035 - 0.054 inch). Select the proper reverse clutch snap ring to achieve specifications:
44. To complete the assembly, reverse clutch and overdrive clutch must be removed.
45. Install the #2 needle bearing (note 3 small tabs up) (1).
46. Install the underdrive shaft assembly (1).
47. Install the #3 thrust washer (1) to the underdrive shaft assembly (2). Be sure five tabs are seated properly.
48. Install the #3 thrust plate (3) (note 3 tabs) to the bottom of the overdrive shaft assembly (1). Retain with petrolatum or transmission assembly gel (2).
49. Refer to the exploded view as necessary when performing the following steps.
50. Install the overdrive shaft assembly (1).
51. Reinstall overdrive and reverse clutch as shown. Rechecking these clutch clearances is not necessary.