Input Clutch Assembly - Assembly

ASSEMBLY

Special Tools:










NOTE: When installing the OD / Reverse piston belleville spring, orientate it such that it contacts a new surface on the piston.










1. Install the belleville spring and snap ring loosely onto the OD / Reverse piston (3).
2. Using an Arbor Press (1) and tool (2) compress the belleville spring just enough to install the snap ring.










NOTE: 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.

3. Check the transmission lubrication check valve (20) located in the input shaft using shop air. The valve should only allow air flow in one direction. If the valve allows no air flow, or air flow in both directions, the valve will need to be replaced.
4. Lubricate all seals with Mopar(R) ATF +4, Automatic Transmission Fluid, prior to installation.
5. Assemble the OD/reverse piston (15) onto the input clutch hub (1). (Figure 2)
6. Assemble the input clutch retainer (13) onto the input clutch hub (1).
7. Install the input clutch retainer tapered snap-ring (5) with tapered side up onto the input clutch hub (1).










8. Install Piston Installer (1)(Figure 3) into the input clutch retainer and onto the input clutch hub to guide the inner and outer underdrive piston seals into position.
9. Install the underdrive piston into the input clutch retainer and over the input clutch hub.










10. Install the UD balance piston return spring pack into the input clutch retainer.
11. Install Piston Installer (1)(Figure 4) into the input clutch retainer to guide the UD balance piston seal into position inside the underdrive piston.










NOTE: The UD clutch discs can be identified by their cross-hatched groove pattern (two sets of parallel grooves at 90 degrees to each other). The UD separator plates can be identified by semi-circular cutouts on the edges of the teeth. The reverse clutch and UD clutch use common separator plates.

12. Install the UD balance piston (3) into the input clutch retainer and the underdrive piston.
13. Using Spring Compressor (2), compress the UD return spring pack and secure the piston in place with the snap-ring. (Figure 5)
14. Install the underdrive clutch pack into the input clutch retainer.










15. Install the UD reaction plate lower flat snap-ring (16) (Figure 6). The correct snap-ring can be identified by the two tabbed ears.
16. Install the UD reaction plate (15) into the input clutch retainer. The reaction plate is to be installed with the big step down.
17. Install the UD reaction plate upper tapered snap-ring (14) with tapered side up.










18. Install the input clutch assembly into Input Clutch Pressure Fixture (2). (Figure 7)










19. Mount a dial indicator (1) on the input clutch hub. Push down on the UD clutch discs and zero the indicator against the underdrive clutch discs (Figure 8). 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 0.84-1.54 mm (0.033-0.061 in.). The reaction plate is not selective. If the clutch clearance is not within specification, replace the reaction plate along with all the friction and steel discs.










20. Install the overdrive clutch pack (13)(Figure 9) into the input clutch retainer. The overdrive steel separator plates can be identified by the lack of the half-moon cuts in the locating tabs. The OD clutch discs can be identified by their radial groove pattern.The OD clutch discs can be identified by their radial groove pattern.
21. Install the overdrive clutch wavy snap-ring (3)(Figure 9) with the two tabbed ears into the OD/reverse piston.
22. Install the OD/reverse pressure plate (4)(Figure 9) into the input clutch retainer. The pressure plate is non-directional.
23. Install the OD/reverse reaction plate flat snap-ring (6) into the OD/reverse piston.










24. Mount a dial indicator (1) on the input clutch hub and zero the indicator against the OD/reverse pressure plate (2). (Figure 10). 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 1.103-1.856 mm (0.043-0.073 in.). The pressure plate is not selective. If the clutch clearance is not within specification, replace the pressure plate along with all the friction and steel discs.

25. Install the reverse clutch pack into the input clutch retainer. (Figure 6)
26. Install the reverse reaction plate into the input clutch retainer.
27. Install the reverse reaction plate selective snap-ring into the input clutch retainer.










28. 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 (2) (Figure 11). 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 in.). Adjust as necessary. Install the chosen snap-ring and re-measure to verify selection.

NOTE: The 545RFE uses one of three (3) different selective snap rings. They are identified by the end cuts (either straight [square] cut or "butterfly" [S-curved] cut):

SELECTABLE END PLAY SNAP RINGS
- One Square End, One Buttery Fly End = 1.55 mm (0.061 in.)
- Both Ends Square Cut = 1.85 mm (0.073 in)
- Both Ends Buttery Fly Cut = 2.2 mm (0.087 in.)










29. Remove the reverse clutch pack (8)(Figure 12) from the input clutch retainer.
30. Install the number 2 thrust bearing (18) onto the underdrive hub (17) with outer race against the hub with petroleum jelly.
31. Install the underdrive hub (17) into the input clutch retainer.
32. Install the number 3 thrust bearing (1)(Figure 12) into the overdrive hub (2) with the outer race against the hub with petroleum jelly.
33. Install the overdrive hub (2) into the input clutch retainer.
34. Install the number 4 thrust bearing (5) into the reverse hub with outer race against the hub with petroleum jelly.
35. Install the reverse hub (7) into the input clutch retainer.
36. Install the complete reverse clutch pack (8).
37. Install the reverse reaction plate (9) and snap-ring (10).
38. Push up on reaction plate to allow reverse clutch to move freely.