Cover Assembly

Cover Assembly

Special Tool(s):

Disassembly
1. Remove the bolt and the turbine shaft speed (TSS) sensor.





2. Using Forward/Overdrive Spring Compressor 307-584/1 and 307-584/2, compress the intermediate clutch return spring, using a press and remove the snap ring.





3. Remove Forward/Overdrive Spring Compressor 307-584/1 and 307-584/2.





4. Remove the intermediate clutch return spring.





5. Remove and discard the intermediate clutch piston.





6. Install Forward/Overdrive Spring Compressor 307-584/2 and Reverse Clutch Piston Compressor 307-588/3, using a press, compress the low/reverse clutch return spring and remove the snap ring.





7. Remove Forward/Overdrive Spring Compressor 307-584/2 and Reverse Clutch Piston Compressor 307-588/3.





8. Remove the low/reverse clutch return spring.





9. Remove and discard the low/reverse clutch piston.





10. Using a suitable tool, remove and discard the 4 Teflon(R) seals.





11. Clean and inspect the cover for damage. Install a new cover if damaged.

Assembly
1. Install Overdrive/Direct Clutch Assembly Seal Installer 307-578/3 on the cover and adjust the special tool to align the bottom edge of the tool with the top edge of the bottom Teflon(R) seal groove.





2. Install a new Teflon(R) seal on Overdrive/Direct Clutch Assembly Seal Installer 307-578/3.





3. Install Overdrive/Direct Clutch Assembly Seal Installer 307-578/2 over 307-578/3. Using special tool 307-578/2, slide the Teflon(R) seal over the cover and into the groove.





4. Remove Overdrive/Direct Clutch Assembly Seal Installer 307-578.
^ Repeat Steps 1, 2, 3 and 4 for the other 3 Teflon(R) seals.





5. Install Overdrive/Direct Clutch Assembly Seal Sizer 307578/1 on the cover to size the 4 Teflon(R) seals.





6. Install Reverse Clutch Piston Seal Protectors 307-588/1 and 307-588/2.





7. Lubricate the sealing surfaces of the low/reverse piston with petroleum jelly and position the low/reverse piston in the cover.
1) Lubricate the seals.
2) Position the low/reverse piston in the cover so that the semicircles in the piston are aligned with the indentation in the cover.





8. Make sure the low/reverse piston bleed hole and semicircle area are aligned with the indentation in the cover and the intermediate cylinder fill hole.
1) Low/reverse piston bleed hole
2) Low/reverse piston semicircle area
3) Cover indentation
4) Intermediate cylinder fill hole





9. Position the low/reverse piston in the cover, make sure that the piston bleed hole stays aligned with the indentation in the cover and push the piston in the cylinder using Reverse Clutch Piston Compressor 307-588/3.





10. Remove Reverse Clutch Piston Seal Protectors 307-588/1 and 307-588/2.





11. Install the low/reverse piston return spring with the tabs facing down.





12. Install Forward/Overdrive Spring Compressor 307-584/2 and Reverse Clutch Piston Compressor 307-588/3.





13. NOTE: Make sure the snap ring is fully seated in the groove before releasing the pressure on the return spring.

Compress the low/reverse piston return spring, install the snap ring and remove Forward/Overdrive Spring Compressor 307-584/2 and Reverse Clutch Piston Compressor 307-588/3.





14. Lubricate the sealing surfaces on the intermediate clutch piston with petroleum jelly.





15. Install the intermediate clutch piston.





16. Install the intermediate clutch piston return spring.





17. NOTE: Make sure the snap ring is fully seated in the groove before releasing the pressure on the return spring.

Install Forward/Overdrive Spring Compressor 307-584/1 and 307-584/2. Using a press, compress the intermediate clutch piston return spring, install the snap ring and remove the special tools.





18. Remove Overdrive/Direct Clutch Assembly Seal Sizer 307-578/1.





19. Lubricate the O-ring seal on the TSS sensor with clean automatic transmission fluid and install the TSS sensor in the cover and install the bolt.
^ Tighten to 12 Nm (9 lb-ft).