Forward Clutch Sprag Assembly

5 Plate Clutch Assembly Built After Feb.9,1987:

6 Plate Clutch Assembly Built After Feb.9,1987:

NOTE: A new 3-4 clutch apply package is now in production starting February 9, 1987. A new 3-4 clutch apply plate (stepped) replaces a flat apply plate. The input housing and shaft assembly is revised with longer housing splines for using the new 3-4 clutch apply plate. A new input internal gear with longer splines on the outside diameter is used. This package also eliminates usage of the longer 3-4 clutch apply ring (now using only the short 3-4 clutch apply ring on all models). New 3-4 backing plates are used. A new internal retaining ring (thinner and end configuration is changed or identification. The changes described here only apply to transmissions built after February 9, 1987 (Julian date 040).

1. Remove forward sprag outer race, then the overrun clutch hub retaining snap ring and clutch hub.

2. Remove sprag assembly wear plate, then the forward clutch retainer and race assembly.

3. Inspect forward clutch sprag assembly for wear, damage, missing retainer caps and weak or broken springs.

4. Inspect overrun clutch hub for spline damage, plugged lubrication holes, damaged tangs and cracks.

5. Inspect forward clutch retainer and race assembly for spline damage, ring groove damage, surface finish damage and loose retainer.

6. Inspect forward sprag outer race for spline damage, surface finish damage and plugged lubrication holes.







7. Install forward clutch sprag assembly into outer race with notches in sprag case facing upward.

8. Install one brass sprag retainer ring onto race and retainer assembly. Ensure flange on retainer ring faces away from retainer.





9. Install race and retainer assembly into sprag assembly as shown in image.

10. Install remaining brass retainer ring onto sprag assembly.

11. Install wear plate onto retainer ring, then the overrun clutch hub onto the wear plate.






12. Install overrun clutch hub retaining snap ring into snap ring groove of race and retainer assembly, then test assembly as shown in image. If sprag assembly turns counterclockwise, sprag assembly should be reassembled correctly.

13. Install forward clutch sprag assembly into input clutch housing.

14. Inspect forward and 3-4 clutch plates for damaged tangs, delamination, wear or heat damage.

15. Inspect forward an 3-4 clutch backing plates for flatness, surface finish damage, burrs or nicks.

16. Inspect forward clutch apply plate and spacer plate for flatness, surface finish damage, burrs or nicks.

16. Inspect forward clutch apply plate and spacer plate for flatness, surface finish damage, burrs or nicks.

17. Inspect 3-4 clutch apply plate for flatness and surface finish damage.





18. Inspect 3-4 clutch ring retainer plate for bent tangs and flatness. Refer to clutch plate application charts, when performing remaining steps.

19. A forward clutch which requires five steel forward clutch plates will use a single thick apply plate. A forward clutch which requires four steel forward clutch plates will use a thin apply plate and thick spacer plate.

20. Install spacer plate into the input clutch housing, if necessary.

21. Install waved steel forward clutch late into input clutch housing.

22. Install remaining forward clutch plates into input clutch housing. Start with composition plate and alternate with steel plate.

Transmission Built After Feb.9,1987:

23. Install forward clutch backing plate with chamfered side up. A new forward clutch backing plate is now in production. The new backing plate is smaller in diameter also the input housing and shaft assembly with larger splines that match the forward clutch backing plate splines, Fig. 586 is used. The new forward clutch backing plate or the new input housing and shaft assembly cannot be used on transmissions.

a. With the overrun clutch and the forward clutches fully assembled in the input housing and shaft assembly, measure backing plate travel.

b. Using a feeler gauge as shown in image measure backing plate travel.

c. Proper forward clutch backing plate travel should be 0.030-0.063 inch.

d. Select the proper forward clutch backing plate from image, to obtain specified travel.

24. Install forward clutch retainer ring. The forward clutch retainer ring is a small ring with a larger gap.

Transmission Built After Feb.9,1987:

25. Install 3-4 clutch ring retainer plate, then the 3-4 clutch apply plate and clutch plates. Start with the composition plate and alternate with steel.

26. Install 3-4 clutch backing plate and retainer ring with chamfered side up.