Rear Clutch
DISASSEMBLY1. Remove thrust washer from forward side of clutch retainer.
2. Remove input shaft front/rear seal rings.
3. Remove selective clutch pack snap-ring (Fig. 170).
4. Remove top pressure plate, clutch discs, steel plates, bottom pressure plate and wave snap-ring and wave spring (Fig. 170).
5. Remove clutch piston with rotating motion.
6. Remove and discard piston seals.
7. Remove input shaft snap-ring (Fig. 171). It may be necessary to press the input shaft in slightly to relieve tension.on the snap-ring
8. Press input shaft out of retainer with shop press and suitable size press tool. Use a suitably sized press tool to support the retainer as close to the input shaft as possible.
CLEANING
Clean the clutch components with solvent and dry them with compressed air.
INSPECTION
Check condition of the input shaft seal rings. It is not necessary to remove or replace rings unless they are broken, cracked, or no longer securely hooked together.
Inspect the input shaft splines and machined surfaces. Very minor nicks or scratches can be smoothed off with crocus cloth. replace the shaft if the splines are damaged, or any of the machined surfaces are severely scored.
Replace the clutch discs if warped, worn, scored, burned/charred, the lugs are damaged, or if the facing is flaking off.
Replace the steel plates and the pressure plate if heavily scored, warped, or broken. Be sure the driving lugs on the discs and plates are also in good condition. The lugs must not be bent, cracked or damaged in any way.
Replace the piston spring and wave spring if either part is distorted, warped or broken.
Check the lug grooves in the clutch retainer. The steel plates should slide freely in the slots. Replace the retainer if the grooves are worn or damaged. Also check action of the retainer check ball. The ball must move freely and not stick.
Inspect the piston and retainer seal surfaces for nicks or scratches. Minor scratches can be removed with crocus cloth. However, replace the piston and/or retainer if the seal surfaces are seriously damaged.
Check thrust washer condition. Washer thickness should be 1.55 to 1.60 mm (0.061 to 0.063 inch). Replace the washer if worn or damaged.
Check condition of the two seal rings on the input shaft and the single seal ring on the piston retainer hub. Replace the seal rings only if severely worn, cracked, or cannot be hooked together.
ASSEMBLY
1. Soak clutch discs in transmission fluid while assembling other clutch parts.
2. Install new seal rings on clutch retainer hub and input shaft if necessary (Fig. 172) and (Fig. 173).
a. Be sure clutch hub seal ring is fully seated in groove and is not twisted.
3. Lubricate splined end of input shaft and clutch retainer with transmission fluid. Then press input shaft into retainer. Use a suitably sized press tool to support retainer as close to input shaft as possible.
4. Install input shaft snap-ring (Fig. 163).
5. Invert retainer and press input shaft in opposite direction until snap-ring is seated (Fig. 174).
6. Install new seals on clutch piston. Be sure lip of each seal faces interior of clutch retainer.
7. Lubricate lip of piston seals with generous quantity of Mopar Door Ease. Then lubricate retainer hub and bore with light coat of transmission fluid.
8. Install clutch piston in retainer. Use twisting motion to seat piston in bottom of retainer. A thin strip of plastic (about 0.020 inch thick), can be used to guide seals into place if necessary.
CAUTION: Never push the clutch piston straight in. This will fold the seals over causing leakage and clutch slip. In addition, never use any type of metal tool to help ease the piston seals into place. Metal tools will cut, shave, or score the seals.
9. Install piston spring in retainer and on top of piston (Fig. 175). Concave side of spring faces downward (toward piston).
10. Install wave spring in retainer (Fig. 175). Be sure spring is completely seated in retainer groove.
11. Install bottom pressure plate (Fig. 162). Ridged side of plate faces downward (toward piston) and flat side toward clutch pack.
12. Install first clutch disc in retainer on top of bottom pressure plate. Then install a clutch plate followed by a clutch disc until entire clutch pack is installed (4 discs and 3 plates are required) (Fig. 162).
13. Install top pressure plate.
14. Install selective snap-ring. Be sure snap-ring is fully seated in retainer groove.
15. Using a suitable gauge bar and dial indicator, measure clutch pack clearance (Fig. 176).
a. Position gauge bar across the clutch drum with the dial indicator pointer on the pressure plate (Fig. 176).
b. Using two small screw drivers, lift the pressure plate and release it.
c. Zero the dial indicator.
d. Lift the pressure plate until it contacts the snap-ring and record the dial indicator reading.
16. Clearance should be 0.559 - 0.914 mm (0.022 - 0.036 inch). If clearance is incorrect, steel plates, discs, selective snap-ring and pressure plates may have to be changed. The selective snap-ring thicknesses are:
- 0.107-0.109 inch
- 0.098-0.100 inch
- 0.095-0.097 inch
- 0.083-0.085 inch
- 0.076-0.078 inch
- 0.071-0.073 inch
- 0.060-0.062 inch
17. Coat rear clutch thrust washer with petroleum jelly and install washer over input shaft and into clutch retainer (Fig. 177). Use enough petroleum jelly to hold washer in place.