Direct Clutch
DISASSEMBLYSeparate Direct Clutch From Forward Clutch:
1. Remove direct clutch from forward clutch.
Removing Clutch Drum Thrust Washer:
2. Remove clutch drum thrust washer.
3. Check clutch piston stroke length as outlined in following steps.
Mount Direct Clutch On Overdrive Support:
4. Mount direct clutch on overdrive support assembly.
Checking Direct Clutch Clutch Piston Stroke Length:
5. Mount dial indicator on clutch and position indicator plunger on clutch piston.
6. Apply 57 - 114 psi air pressure through feed hole in overdrive support and note piston stroke length. Check stroke at least twice.
7. Piston stroke length should be 1.37 mm - 1.67 mm (0.054 - 0.065 inch). If stroke length is incorrect, either the clutch pack retainer or clutch discs will have to be replaced.
Removing Clutch Pack Snap Ring:
8. Remove clutch pack snap ring and remove retainer and clutch pack from drum.
Removing Piston Return Spring:
9. Compress clutch piston return springs with tool 7538 and remove clutch piston snap ring.
10. Remove compressor tool and return spring.
Removing Direct Clutch Piston:
11. Remove clutch piston. Remount clutch on overdrive support. Apply compressed air through piston feed hole in support to remove piston. Use only enough air to ease piston out.
12. Remove and discard clutch piston O-rings.
13. Measure clutch disc thickness. Minimum allowable thickness is 1.84 mm (0.0724 in). Replace clutch pack if any disc is below minimum thickness.
Checking Piston Return Spring Length:
14. Measure free length of piston turn springs with springs in retainer. Length should be 21.32 mm (0.839 inch). Replace return springs if not within specification.
Testing Piston Check Ball Seating:
15. Check clutch piston check ball. Shake piston to see if ball moves freely. Then check ball seating by applying low pressure compressed air to ball inlet as shown. Air should not leak Past check ball.
16. Measure inside diameter of clutch drum bushing. Inside diameter should be no more than 53.97 mm (2.1248 inch). Replace drum if bushing inside diameter is greater than specified.
ASSEMBLY
Direct Clutch Components AW-4 Automatic Transmission:
1. Lubricate and install replacement O-rings on clutch piston.
2. Install clutch piston in drum and install return springs on piston.
Removing Piston Return Spring:
3. Compress piston return springs with Tool 7538 and install snap ring. Be sure snap ring end gap is not aligned with spring retainer tab.
Installing Direct Clutch Discs And Plates:
4. Install clutch discs and plates. Install plate then disc until all plates and discs are installed. Four plates and discs are required.
Install Clutch Pack Retainer:
5. Install clutch pack retainer in drum.
6. Install clutch pack snap ring.
Checking Direct Clutch Assembled Height:
7. Check snap ring position. If necessary, shift snap ring until end gap is not aligned with any notches in clutch drum.
Mount Direct Clutch On Overdrive Support:
8. Lubricate clutch drum thrust washer with petroleum jelly and install it in drum.
9. Mount direct clutch assembly on forward clutch assembly and check assembled height. Height should be 70.3 to 71.5 mm (2.767 to 2.815 inch).
10. If assembled height is incorrect, clutches are not seated.