Output Shaft and Direct Clutch Cylinder

Output Shaft and Direct Clutch Cylinder








Special Tool(s)





Material





Output Shaft and Hub Disassembled View








Direct Clutch Disassembled View

Disassembly





1. NOTE: The index mark on the output shaft must be aligned with the index mark on the output shaft ring gear during the assembly procedure.

Remove the ring gear snap ring.





2. Separate the ring gear and output shaft.





3. Remove the three output shaft seal rings.





4. Remove the output shaft hub snap ring and the output shaft hub.





5. Remove the two direct clutch seal rings.





6. Remove the No. 7 direct clutch inner bearing support.
1. Remove the direct clutch hub.
2. Remove the No. 7 direct clutch inner bearing support.
7. Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with a crocus cloth. Install a new clutch cylinder if badly scored or damaged.
8. Check the fluid passages in the clutch cylinder for obstructions. Clean out all fluid passages. Inspect the clutch piston for scores and install new if necessary. Inspect the check balls for freedom of movement and correct seating.
9. Check clutch release spring for distortion and cracks. Install a new spring (including wave spring) if distorted or cracked.
10. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Install new parts if they are deeply scored or burred.
11. Check the clutch plates for flatness and fit on the clutch hub serrations. Discard any plate that does not slide freely on the serrations or that is not flat.
12. Check the clutch hub thrust surfaces for scores and clutch hub splines for wear.





13. Remove the direct clutch pack.
1. Remove the selective retaining ring.
2. Remove the direct clutch pack.





14. Using the special tool, compress the piston return spring and remove the snap ring.





15. WARNING: Wear safety glasses when using compressed air.

NOTE: If necessary, use regulated compressed air 207 kPa (30 psi) maximum pressure to remove the clutch piston.

Remove the support and spring assembly and piston.





16. Remove the inner piston seal.





17. Remove the outer piston seal.

Assembly





1. NOTE: Lubricate the direct clutch piston inner seal and seal protector with petroleum jelly.

Using the special tool, install the inner piston seal.
^ Install the seal with sealing lip facing down.





2. Install the clutch piston outer seal so that when the piston is installed the sealing lip points toward the bottom of the cylinder.





3. NOTE: Coat the inner and outer direct clutch piston seals, clutch cylinder sealing area and piston inner sealing area with petroleum jelly.

Using the special tool, install the direct clutch piston.
4. Install the piston return spring and retainer assembly.





5. Using the special tool, compress the piston return spring and install the retaining ring.





6. NOTE: Before assembly, soak new clutch discs in clean automatic transmission fluid.

Install the clutch pack retaining ring.
1. Alternate external spline (steel) plates and internal spline (friction) plates, starting with a steel plate and ending with the friction plate.
2. Install the clutch pack retaining ring.





7. Use a feeler gauge to check the clearance between the clutch pack selective retaining ring and the pressure plate.
^ If the clearance is not within specifications, install the correct size retaining ring and recheck the clearance.





Selective Retaining Ring





8. Install the direct clutch hub.
1. Install the No. 7 direct clutch inner bearing support.
2. Install the direct clutch hub.

NOTE: Inspect the output shaft bearing surfaces for scores. Inspect the output shaft splines for wear. Inspect all bushings.





9. Using the special tools, install the first direct clutch seal ring.





10. Using the special tools, install the second direct clutch seal ring.





11. After both new seals have been installed, use the special tool to size the seals.





12. Install the output shaft hub.
^ Position the output shaft hub.
^ Install the retaining ring.





13. Install the three output shaft seal rings.





14. Install the No. 8 needle bearing on the direct clutch cylinder.





15. NOTE: Direct clutch cylinder may be installed after the output shaft ring gear is installed to the output shaft hub.

Assemble the direct clutch on the output shaft.





16. CAUTION: The index mark on the output shaft must be aligned with the index mark on the output shaft ring gear.

Align the index marks on output shaft and the output shaft ring gear and install the ring gear on the output shaft.