Overdrive Planetary Gear and Clutch

Overdrive Planetary Gear And Clutch Components AW-4 Automatic Transmission:

DISASSEMBLY

Checking One-Way Clutch:

1. Check operation of one-way clutch in clutch drum. Hold drum and turn planetary shaft clockwise and counterclockwise. Shaft should turn clockwise freely but lock when turned counterclockwise. Replace one-way clutch if necessary.

Removing Overdrive Clutch From Gear:

2. Remove overdrive clutch from planetary gear.
3. Measure stroke length of overdrive clutch piston as follows:

Assembling Converter, Pump And Clutch For Test:

a. Mount oil pump on torque converter. Then mount clutch on oil pump.
b. Install a suitable threaded bolt/rod into oil pump for use in mounting Miller Tool C-3339 dial indicator components securely.
c. Mount dial indicator on the bolt/rod and position the dial indicator squarely on the clutch piston.
d. Apply compressed air through clutch feed hole in oil pump and note piston stroke length. Stroke length should be 1.85 - 2.15 mm (0.0728 -0.0846 inch).

Removing Clutch Drum Bearing And Race:

4. Remove thrust bearing and race assembly from clutch drum.

Removing Clutch Pack Snap Ring:

5. Remove clutch pack snap ring and remove the clutch pack.
6. Measure overdrive clutch disc thickness. Minimum allowable thickness is 1.84 mm (0.07241 inch).
7. If the clutch pack stroke length is out of specification or any clutch disc fails to meet the minimum thickness, new discs will need to be installed during assembly.

Removing Clutch Piston Snap Ring:

8. Compress piston return spring with Tool 7538. Remove snap ring and remove compressor tool.
9. Remove the piston return springs.

Removing Overdrive Clutch Piston:

10. Mount oil pump on converter. Then mount clutch on oil pump.
11. Hold clutch piston by hand and apply compressed air through oil pump feed hole to ease piston out. Apply only enough air pressure to remove piston.

Checking Piston Return Spring Length:

12. Measure free length of piston return springs with springs in retainer. Length should be 16.8 mm (0.661 inch). Replace spring and retainer assembly if necessary.

Testing Clutch Piston Check Ball:

13. Check clutch piston check ball. Shake piston to see if ball moves freely. Then check ball sealing by applying low pressure compressed air to ball inlet as shown. Air should not leak past check ball.

Checking Clutch Drum Bushings:

14. Check inside diameter of clutch drum bushings with bore gauge or inside micrometer. Maximum inside diameter is 27.11 mm (1.0673 inch). Replace drum if bushing inside diameter is greater than specified.

Removing Ring Gear Bearing And Race:

15. Remove bearing and race from ring gear.

Removing Ring Gear Hub:

16. Remove snap ring from ring gear and remove ring gear hub.

Remove Planetary Gear Race:

17. Remove race from planetary gear.

Removing Snap Ring And Retaining Plate:

18. Remove snap ring and remove retaining plate.

Removing One-Way Clutch:

19. Remove one-way clutch and outer race as assembly. Then separate race from clutch.

Removing Planetary Thrust Washer:

20. Remove thrust washer.

Checking Planetary Bushing:

21. Check inside diameter of planetary gear bushing. Maximum inside diameter is 11.27 mm (0.4437 inch). Replace planetary gear if bushing inside diameter is greater then specified.

ASSEMBLY

Install Planetary Thrust Washer:

1. Install thrust washer in planetary gear. Grooved side of washer faces up and toward front.
2. Install clutch race into planetary gear.

Assembling One-Way Clutch And Race:

3. Install one-way clutch into the outer race. Be sure flanged side of clutch is facing upward.
4. Install clutch retaining plate and snap ring in planetary gear.
5. Coat planetary race with petroleum jelly and install it on planetary gear. Outside diameter of race should be 41.8 mm (1.646 inch); inside diameter is 27.1 mm (1.067 inch).
6. Install hub in planetary ring gear and install snap ring.

Install Ring Gear Bearing And Race:

7. Coat race and bearing with petroleum jelly and install in planetary ring gear.
8. Verify bearing/race size. Outside diameter of race is 47.8 mm (1.882 inch) and inside diameter is 24.2 mm (0.953 inch). Outside diameter of bearing is 46.8 mm (1.843 inch) and inside diameter is 26 mm (1.024 inch).
9. Lubricate new clutch piston O-rings with MOPAR Door Ease, or Ru-Glyde. Then install rings on clutch piston and install piston in clutch drum.

Installing Piston Return Springs:

10. Install piston return springs in clutch piston.

Installing Clutch Piston Snap Ring:

11. Install piston snap ring. Compress piston return springs with Tool 7538 and shop press.

Installing Overdrive Clutch Discs And Plates:

12. Install overdrive clutch pack in drum. Install steel plate first, then a disc. Continue installation sequence until required number of discs and plates have been installed.

Installing Retainer And Snap Ring:

13. Install clutch pack retainer with flat side facing downward. Then install retainer snap ring. Compress springs with suitable tool.

Installing Clutch Drum Bearing And Race Assembly:

14. Install clutch drum bearing and race assembly. Be sure bearing rollers face upward as shown. Outside diameter of assembled bearing and race is 50.2 mm (1.976 inch). Inside diameter is 28.9 mm (1.138 inch).
15. Install clutch on planetary gear.
16. Verify one-way clutch operation. Hold drum and turn planetary shaft clockwise and counterclockwise. Shaft should turn clockwise freely but lock when turned counterclockwise.