Input Clutch Assembly
DISASSEMBLYFig. 98:
1. Remove the reverse reaction plate selective snap-ring from the input clutch retainer (Fig. 98).
2. Remove the reverse reaction plate from the input clutch retainer.
3. Remove the reverse hub and reverse clutch pack from the input clutch retainer.
4. Remove the number 4 bearing from the overdrive hub.
5. Remove the overdrive hub from the input clutch retainer (Fig. 98).
6. Remove the number 3 bearing from the underdrive hub.
7. Remove the OD/reverse reaction plate snap-ring from the input clutch retainer.
8. Remove the underdrive hub, overdrive clutch, and overdrive reaction plate from the input clutch retainer (Fig. 98).
NOTE: The overdrive friction discs and steel discs are thicker than the matching components in the underdrive and reverse clutches.
9. Remove the number 2 bearing from the input clutch hub.
10. Remove the overdrive clutch wave snap-ring from the input clutch retainer.
11. Remove the UD/OD reaction plate tapered snap-ring from the input clutch retainer.
12. Remove the UD/OD reaction plate from the input clutch retainer.
13. Remove the UD/OD reaction plate flat snap-ring from the input clutch retainer (Fig. 98).
Fig. 100:
14. Remove the underdrive clutch pack from the input clutch retainer (Fig. 100).
Fig. 99:
15. Using Spring Compressor 8251, compress the UD/0D balance piston and remove the snap-ring from the input clutch hub (Fig. 99).
16. Remove the UD/OD balance piston and piston return spring from the input clutch retainer (Fig. 100).
17. Remove the underdrive piston from the input clutch retainer (Fig. 100).
NOTE: Both the UD/OD balance piston and the underdrive piston have seals molded onto them. If the seal is damaged, do not attempt to install a new seal onto the piston. The piston/seal must be replaced as an assembly.
18. Remove the input clutch retainer tapered snap-ring.
19. Separate input clutch retainer from input clutch hub.
20. Separate OD/reverse piston from input clutch hub retainer (Fig. 100).
21. Remove all seals and O-rings from the input shaft and input hub. The O-rings on the input hub are color coded. Be sure to make note of which O-ring belongs in which location.
ASSEMBLY
1. Install all new seals and O-rings onto the input shaft and input hub. The O-rings on the input hub are color coded. Be sure to install the correct O-ring in the correct location.
2. Lubricate all seals with Mopar ATF+3, type 7176 prior to installation.
3. Assemble the OD/reverse piston onto the input clutch hub (Fig. 100).
4. Assemble the input clutch retainer onto the input clutch hub.
5. Install the input clutch retainer tapered snap-ring with tapered side up onto the input clutch hub.
Fig. 101:
6. Install Piston Guides 8504 into the input clutch retainer (Fig. 101) and onto the input clutch hub to guide the inner and outer underdrive piston seals into position.
7. Install the underdrive piston into the input clutch retainer and over the input clutch hub (Fig. 100).
8. Install the MOD balance piston return spring pack into the input clutch retainer.
Fig. 102:
9. Install Piston Guide 8252 into the input clutch retainer (Fig. 102) to guide the MOD balance piston seal into position. inside the underdrive piston.
10. Install the UD/OD balance piston into the input clutch retainer and the underdrive piston.
Fig. 103:
11. Using Spring Compressor 8251, compress the MOD return spring pack and secure the piston in place with the snap-ring (Fig. 103).
12. Install the underdrive clutch pack into the input clutch retainer (Fig. 100).
13. Install the UD/OD reaction plate lower flat snap-ring (Fig. 98). The correct snap-ring can be identified by the two tabbed ears.
14. Install the UD/OD reaction plate into the input clutch retainer. The reaction plate is to be installed with the big step down. The reaction plate is also selectable and should be changed to achieve the correct clutch clearances.
15. Install the UD/OD reaction plate upper tapered snap-ring with tapered side up.
Fig. 104:
Fig. 105:
16. Install the input clutch assembly into Input Clutch Pressure Fixture 8260 (Fig. 104). Mount a dial indicator to the assembly, push down on the clutch discs and zero the indicator against the underdrive clutch discs (Fig. 105). Apply 20 psi of air pressure to the underdrive clutch and record the dial indicator reading. Measure and record UD clutch pack measurement in four 4 places, 90 ° apart. Take average of four measurements and compare with UD clutch pack clearance specification. The correct clutch clearance is 0.76 - 1.16 mm (0.030 - 0.063 inch). Adjust as necessary. Install the chosen reaction plate and remeasure to verify selection.
17. Install the overdrive clutch pack into the input clutch retainer (Fig. 98). The overdrive steel separator plates can be identified by the lack of the half-moon cuts in the locating tabs.
18. Install the overdrive clutch wavy snap-ring with the two tabbed ears into the input clutch retainer.
19. Install the OD/reverse reaction plate into the input clutch retainer. The reaction plate is non-directional (Fig. 98).
20. Install the OD/reverse reaction plate flat snap-ring into the input clutch retainer.
Fig. 106:
21. Mount a dial indicator to the assembly and zero the indicator against the OD/reverse reaction plate (Fig. 106). Apply 20 psi of air pressure to the overdrive clutch and record the dial indicator reading. Measure and record OD clutch pack measurement in four 4 places, 90 ° apart. Take average of four measurements and compare with OD clutch pack clearance specification. Verify that the clutch clearance is 1.016 - 1.135 mm (0.040 - 0.065 inch).
22. Install the reverse clutch pack into the input clutch retainer (Fig. 98).
23. Install the reverse reaction plate into the input clutch retainer.
24. Install the reverse reaction plate selective snap-ring into the input clutch retainer.
Fig. 107:
25. Mount a dial indicator to the assembly, push down on the clutch discs, pull up on the reaction plate to ensure the plate is properly seated and zero the indicator against, the reverse clutch discs (Fig. 107). Apply 20 psi of air pressure to the reverse clutch and record the dial indicator reading. Measure and record Reverse clutch pack measurement in four 4. places, 90 ° apart. Take average of four measurements and compare with Reverse clutch pack clearance specification. The correct clutch clearance is 0.81 - 1.24 mm (0.032 - 0.049 inch). Adjust as necessary. Install the chosen snap-ring and re-measure to verify selection.
26. Remove the reverse clutch pack from the input clutch retainer.
27. Install the number 2 bearing onto the underdrive hub with flat side up/forward with petroleum jelly.
28. Install the underdrive hub into the input clutch retainer.
29. Install the number 3 bearing into the overdrive hub with the flat side up/forward with petroleum jelly.
30. Install the overdrive hub into the input clutch retainer.
31. Install the number 4 bearing into the reverse hub with flat side up/forward with petroleum jelly.
32. Install the reverse hub into the input clutch retainer.
33. Install the complete reverse clutch pack.
34. Install the reverse reaction plate and snap-ring.
35. Push up on reaction plate to allow reverse clutch to move freely.