Output Shaft: Service and Repair
Part 1 Of 2:
DISASSEMBLY
1. Remove the ring gear snap ring.
2. Separate the (A) ring gear and (B) output shaft.
3. Remove the (A) output shaft hub snap ring and the (B) output shaft hub.
4. Remove the three output shaft seal rings.
5. Remove the two direct clutch seal rings.
6. Remove the (A) direct clutch hub and the (B) bearing and direct clutch inner bearing support.
7. Inspect clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Replace clutch cylinder if badly scored or damaged.
8. Check fluid passage in clutch cylinder for obstructions. Clean out all fluid passages. Inspect clutch piston for scores and replace if necessary. Inspect check balls for freedom of movement and proper seating.
9. Check clutch release spring for distortion and cracks. Replace 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. Replace all parts that are deeply scored or burred.
11. Check clutch plates for flatness and fit on clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat.
12. Check clutch hub thrust surfaces for scores and clutch hub splines for wear.
13. Remove the (A) direct clutch pack retaining ring and the (B) direct clutch pack.
14. Use (A) Clutch Spring Compressor T65L-77515-A to compress the piston return spring and remove the (B) snap ring.
15. Remove the support and spring assembly and piston.
WARNING: WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR.
NOTE: If necessary, use regulated compressed air (207 kPa [30 psi] max pressure) to remove the clutch piston.
16. Remove the inner piston seal.
17. Remove the outer piston seal.
ASSEMBLY
1. Position (A) Direct Clutch Lip Seal Protector T80L-77234-A over the clutch cylinder hub and install the (B) inner piston seal.
- Install the seal with sealing lip facing down.
NOTE: Lubricate direct clutch piston inner seal and seal protector with petroleum jelly.
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. Use (A) Direct Clutch Lip Seal Protector T80L-77254-A to install the (B) direct clutch piston.
NOTE: Coat inner and outer direct clutch piston seals, clutch cylinder sealing area and piston inner sealing area with petroleum jelly.
4. Install the piston return spring and retainer assembly.
5. Use (A) Clutch Spring Compressor T65L-775 1 5-A to compress the piston return spring and install the (B) retaining ring.
6. Install the (A) clutch pack and the (B) clutch pack retaining ring.
- Alternate external spline (steel) plates and internal spline (friction) plates, starting with a steel plate and ending with the steel pressure plate.
NOTE: Before assembly, soak new clutch discs should be soaked in transmission fluid for 15 minutes.
7. Use a (A) feeler gauge to check the clearance between the (B) clutch pack retaining ring and the (C) pressure plate.
- If the clearance is not within specifications, install the correct size retaining ring and recheck clearance.
8. Install the washer and the (B) No. 7 needle bearing on the (A) direct clutch hub and install the direct clutch hub.
- Install the needle bearing with the black side up, toward direct clutch hub.
NOTE: Inspect the output shaft bearing surfaces for scores. Inspect the output shaft splines for wear. Inspect all bushings.
9. Install the two direct clutch seal rings.
CAUTION: Make sure seals are lapped correctly.
10. Install the output shaft hub.
(1) Position the output shaft hub.
(2) Install the retaining ring.
11. Install the three output shaft seal rings.
12. Install the No. 8 needle bearing on the direct clutch cylinder.
13. Position the (A) direct clutch on the (B) output shaft.
NOTE: Direct clutch cylinder may be installed after the output shaft ring gear is installed to the output shaft hub.
14. Install the ring gear on the output shaft.