Intermediate Clutch Assembly

Intermediate Clutch Assembly

Intermediate Clutch Assembly:

Disassembly
1. Remove the thrust bearing (T6).





2. Remove the intermediate clutch plate snap ring.





3. NOTE: Inspect the friction and steel plates for damage. If damaged, install new components as necessary. If no damage is indicated, the friction and steel plates can be reused.

Remove the intermediate clutch plates.





4. Using the special tool, remove and discard the intermediate clutch return spring retainer.





5. Remove the intermediate clutch return spring top plate.





6. Remove the intermediate clutch return spring.





7. Applying a slight amount of air to the port, remove the intermediate clutch piston.





8. Remove and discard the inner and outer intermediate clutch piston O-ring seals.





Assembly
1. Install new inner and outer intermediate clutch piston O-ring seals.





2. Lightly coat the O-ring seals in clean transmission fluid and install the intermediate clutch piston.





3. Install the intermediate clutch return spring.





4. Install the intermediate clutch return spring top plate.





5. Using the special tool, install a new intermediate clutch return spring retainer.





6. If required, install new intermediate clutch plates, starting with the wave spring then a steel plate and alternating between friction and steel plates, and ending with the pressure plate.





7. Install the intermediate clutch plate snap ring.





8. NOTE: All intermediate clutch plates friction and steel are of a wave-type design.

Install the intermediate clutch assembly into the special tool so the dial indicator fits into the opening of the snap ring.





9. With the dial indicator set at zero, lift up on the steel pressure plate so it is against the select fit snap ring. Record this reading as reading A.
10. Rotate the intermediate clutch assembly 180 degrees from the opening of the snap ring, take a second reading and record this reading as reading B.





11. NOTE: If the final measurement is not within specification, install a new snap ring until the correct specification is achieved.

^ 4.6L 3V engine - 0.5-0.9 mm (0.019-0.035 inch)
If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is high, remeasure using a thicker select fit snap ring. If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is low, remeasure using a thinner select fit snap ring.
12. Install the thrust bearing (T6).