Overdrive Brake and Coast Clutch Drum Assembly

Special Tools:

Disassembly








1. CAUTION: If new plates are being used, they should be soaked in clean transmission fluid for at least 30 minutes before assembly.

CAUTION: This is a select fit ring. See assembly procedure if the ring or clutch plate is replaced.

Remove the coast clutch pressure plate.
1 Remove the coast clutch retaining ring.
2 Remove the coast clutch pressure plate.





2. CAUTION: If new clutch plates are being used, they should be soaked in clean transmission fluid for at least 30 minutes before assembly.

CAUTION: Coast clutch friction plates are directional. Note direction of grooves for installation.

Remove the coast clutch disc pack.
- Inspect for wear, replace as necessary.





3. WARNING: Use caution when releasing tool pressure on the rear clutch piston spring. Failure to follow these instructions may result in personal injury.

CAUTION: Do not fully compress the Clutch Spring Compressor or damage to the spring retainer may occur.

Remove the coast clutch piston retaining ring.
1 Use Clutch Spring Compressor to compress the coast clutch piston springs.
2 Remove the coast clutch piston retaining ring.
4. Relieve the direct clutch spring tension and remove the Clutch Spring Compressor.





5. Remove the coast clutch piston springs.
1 Remove the coast clutch piston spring retainer.
2 Remove the 20 clutch piston springs.





6. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air, and make sure drum is facing down as shown. Failure to follow these instructions may result in personal injury.

Remove the coast clutch piston.
- Apply air pressure to the hole in the drum to remove coast clutch piston while blocking other hole with finger.





7. Remove the coast clutch piston inner seal and the coast clutch piston outer seal.
- Clean and replace as necessary.

Assembly





1. CAUTION: The lip seals must be positioned as shown. Care must be taken to prevent rollover of the lip seal.

Install the new coast clutch piston inner and outer seal.





2. CAUTION: Lubricate the coast clutch piston inner and outer seal.

Install the coast clutch piston into Coast Clutch Outer Seal Sizing Tool.
3. Inspect the coast clutch components for damage or wear. Replace as necessary.
- Inspect the drum band surface, bushing, and thrust surfaces for scores. Minor scores may be removed with a crocus cloth. Badly scored parts must be replaced.
- Inspect the clutch piston bore and the clutch piston and the piston inner and outer bearing surfaces for scores.
- Cheek the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
- Inspect the clutch plates for wear, scoring and fit on the clutch hub serrations. Replace all plates that are badly scored, worn or do not fit freely in the hub serrations.
- Inspect the clutch pressure plate for scores on the clutch plate surface. Cheek the clutch release spring(s) for distortion.





4. Verify the check ball in the overdrive band brake and coast clutch drum is free to move and clear of debris.





5. Carefully remove the coast clutch piston from the Coast Clutch Outer Seal Sizing Tool.





6. CAUTION: Care must be taken to prevent damage to the seals during installation.

Install the coast clutch piston into the overdrive band brake and coast clutch drum.





7. Install the coast clutch piston springs.
1 Install the 20 coast clutch piston springs.
2 Position the coast clutch piston spring retainer on the coast clutch piston springs.





8. CAUTION: Do not fully compress the Clutch Spring Compressor or damage to the coast clutch piston spring retainer may occur.

Install the coast clutch piston spring retainer ring.
1 Use Clutch Spring Compressor to compress the coast clutch piston springs.
2 Install the coast clutch piston retaining ring.
9. Relieve the direct clutch spring tension and remove the Clutch Spring Compressor.





10. CAUTION: Coast clutch friction plates are directional and must be installed with grooves clockwise (I.D. to O.D.). The word "TOP" should face up.

CAUTION: If new clutch plates are being used, they should be soaked in clean transmission fluid for at least 30 minutes before assembly.

When installing friction plates, the word "TOP" should face up. If reusing plates, grooves must be installed clockwise. Install the coast clutch disc pack.





11. Install the two steel clutch plates and two friction clutch plates in alternating order starting with a steel clutch plate.





12. CAUTION: The retaining ring is select fit.

Install the coast clutch pressure plate.
1 Install the clutch pressure plate.
2 Install the original coast clutch retaining ring.





13. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Make sure alum is facing down as shown. Failure to follow these instructions may result in personal injury.

Note: The coast clutch piston is applied with air pressure and released when the air is removed.

Air check the assembly.
- Apply air pressure to the hole in the drum while blocking the other hole with a finger.





14. Check the coast clutch disc pack free play.
1 Push down on the coast clutch pressure plate.





2 Check clearance between the coast clutch retaining ring and coast clutch pressure plate. Clearance should be 1.3 - 2.0 mm (0.051 - 0.079 inch). If clearance is not within the specification, replace with the proper coast clutch retaining ring that will correct free play adjustment.