Input Clutch Assembly
AUTOMATIC TRANSMISSION - 42RLEINPUT CLUTCH ASSEMBLY
DISASSEMBLY
1. Mount input clutch assembly to Input Clutch Pressure Fixture (Tool 8391).
Fig. 156 Tapping Reaction Plate:
2. Tap down (2) reverse clutch reaction plate (4) to release pressure from snap ring (Fig. 156).
Fig. 157 Reverse Clutch Snap Ring:
3. Remove reverse clutch snap ring (3) (Fig. 157).
Fig. 158 Pry Reverse Clutch Reaction Plate:
4. Pry up reverse clutch reaction plate (1) (Fig. 158).
Fig. 159 Reverse Clutch Reaction Plate:
5. Remove reverse clutch reaction plate (1) (Fig. 159).
NOTE: Tag reverse clutch pack for reassembly identification.
Fig. 160 Reverse Clutch Pack:
6. Remove the reverse clutch pack (two fibers/one steel) (1, 2) (Fig. 160).
Fig. 161 OD/Reverse Pressure Plate Snap Ring:
7. Remove the OD/Reverse reaction plate (1) snap ring (3) (Fig. 161).
Fig. 162 OD/Reverse Reaction Plate:
8. Remove OD/Reverse pressure plate (1) (Fig. 162).
Fig. 163 Waved Snap Ring:
9. Remove OD/Reverse reaction plate wave snap ring (2) (Fig. 163).
Fig. 164 Remove OD Clutch Pack:
10. Remove OD shaft/hub and OD clutch pack (1) (Fig. 164).
NOTE: Tag overdrive clutch pack for reassembly identification.
Fig. 165 Overdrive Clutch Pack:
11. Remove the overdrive clutch (1, 3) from the overdrive hub/shaft (2) (Fig. 165).
Fig. 166 #3 and #4 Thrust Washers:
12. Remove and inspect number 3 and 4 thrust plates (1, 3) (Fig. 166).
Fig. 167 Underdrive Shaft Assembly:
13. Remove the underdrive shaft assembly (2) (Fig. 167).
Fig. 168 No 2 Needle Bearing:
14. Remove the number 2 needle bearing (1) (Fig. 168).
Fig. 169 Tapered Snap Ring:
15. Remove the OD/UD reaction plate tapered snap ring (1) (Fig. 169).
NOTE: The OD/UD clutch reaction plate has a step on both sides. The OD/UD clutches reaction plate goes tapered step side up.
Fig. 170 OD/UD Reaction Plate:
16. Remove the OD/UD reaction plate (1) (Fig. 170).
Fig. 171 Remove Last UD Clutch Disc:
17. Remove the first UD clutch disc (1) (Fig. 171).
Fig. 172 UD Clutch Flat Snap Ring:
18. Remove the UD clutch flat snap ring (1) (Fig. 172).
NOTE: Tag underdrive clutch pack for reassembly identification.
Fig. 173 Underdrive Clutch Pack:
19. Remove the UD clutch pack (1, 3) (Fig. 173).
CAUTION: Compress return spring just enough to remove or install snap ring.
Fig. 174 UD Spring Retainer Snap Ring:
20. Using Tool 5059A (4) and an arbor press (2), compress UD clutch piston enough to remove snap ring (3) (Fig. 174).
Fig. 175 UD Return Spring and Retainer:
21. Remove the underdrive spring retainer snap ring (2), spring retainer (1), and spring (4) (Fig. 175).
Fig. 176 Underdrive Clutch Piston:
22. Remove the UD clutch piston (1) (Fig. 176).
Fig. 177 Input Hub Tapered Snap Ring:
23. Remove the input hub tapered snap ring (2) (Fig. 177).
Fig. 178 Tap on Input Hub:
24. Tap on input hub (1) with soft faced hammer (2) and separate input hub from OD/Reverse piston and clutch retainer (Fig. 178).
Fig. 179 Input Hub Removed:
25. Separate the input hub from OD/Reverse piston (5) and clutch retainer (2) (Fig. 179).
Fig. 180 Pull Retainer from Piston:
26. Separate clutch retainer (2) from OD/Reverse piston (1) (Fig. 180).
Fig. 181 Remove Snap Ring:
27. Using Tool 6057 (4) and an arbor press (1), compress OD/Reverse piston (5) return spring just enough to remove snap ring (3) (Fig. 181).
Fig. 182 Return Spring and Snap Ring:
28. Remove the OD/Reverse piston (5) return spring and snap ring (3) (Fig. 182).
Fig. 183 Remove Input Shaft Snap Ring:
29. Remove input shaft (1) to input clutch hub snap ring (3) (Fig. 183).
Fig. 184 Remove Input Shaft:
30. Using a suitably sized socket (2) and an arbor press (1), remove input shaft (5) from input shaft hub (Fig. 184).
ASSEMBLY
Use petrolatum on all seals to ease assembly of components.
Fig. 185 Install Input Shaft:
1. Using an arbor press(2), install input shaft (1) to input shaft hub (2) (Fig. 185).
Fig. 186 Install Input Shaft Snap Ring:
2. Install input shaft snap ring (3) (Fig. 186).
Fig. 187 Return Spring and Snap Ring:
3. Position the OD/Reverse piston return spring (2) and snap ring (3) onto the OD/Reverse piston (1) (Fig. 187).
Fig. 188 Install Snap Ring:
4. Using an arbor press (1) and Tool 6057 (4), install the OD/Reverse piston return spring (6) and snap ring (3) (Fig. 188).
Fig. 189 Install OD/Reverse Piston:
5. Install the OD/Reverse piston (1) assembly to the input clutch retainer (2) (Fig. 189).
Fig. 190 Install Input Shaft Hub Assembly:
6. Install the input hub/shaft assembly (1) to the OD/Reverse piston/clutch retainer assembly (2) (Fig. 190).
Fig. 191 Install Input Hub Tapered Snap Ring:
7. Install input hub tapered snap ring (2) (Fig. 191). Make sure snap ring is fully seated.
Fig. 192 Underdrive Clutch Piston:
8. Install the UD clutch piston (1) (Fig. 192).
Fig. 193 Seal Compressor Special Tool 5067:
9. Install UD piston return spring (1) and Tool 5067 (2) (Fig. 193).
Fig. 194 UD Return Spring and Retainer:
10. Position the UD spring retainer (1) and snap ring (2) on the piston return spring (4) (Fig. 194).
CAUTION: Compress return spring just enough to install snap ring.
Fig. 195 Install UD Spring Retainer and Snap Ring:
11. Using Tool 5059A (6) and an arbor press install the UD spring retainer and snap ring (3) (Fig. 195).
Fig. 196 Underdrive Clutch Pack:
12. Install the UD clutch pack (four fibers/four steels) (1, 3) (Fig. 196). Leave the top disc (2) out until after the snap ring is installed.
Fig. 197 UD Clutch Flat Snap Ring:
13. Install the UD clutch flat snap ring (1) (Fig. 197).
Fig. 198 Install Last UD Clutch Disc:
14. Install the last UD clutch disc (1) (Fig. 198).
Fig. 199 OD/UD Reaction Plate:
15. Install the OD/UD clutch reaction plate (1) (Fig. 199). The OD/UD clutches reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up.
NOTE: Snap ring ends must be located within one finger of the input clutch hub. Be sure that snap ring is fully seated, by pushing with screwdriver, into snap ring groove all the way around.
Fig. 200 Tapered Snap Ring:
16. Install the MOD tapered snap ring (1) (Fig. 200).
Fig. 201 Seating Tapered Snap Ring:
17. Seat tapered snap ring (1) to ensure proper installation (Fig. 201).
Fig. 202 Input Clutch Assembly on Pressure Fixture Tool - 8391:
18. Install input clutch assembly (1) to the Input Clutch Pressure Fixture 8391 (2) (Fig. 202).
Fig. 203 Set Up Dial Indicator to Measure UD Clutch Clearance:
19. Set up dial indicator (1) on the UD clutch pack (2) (Fig. 203).
Fig. 204 Press Down on UD Clutch Pack and Zero Dial Indicator:
20. Using moderate pressure, press down and hold (near indicator) the UD clutch pack (2) with screwdriver or suitable tool and zero dial indicator (1) (Fig. 204). When releasing pressure on clutch pack, indicator reading should advance 0.005 - 0.010 inches.
CAUTION: Do not apply more than 30 psi (206 kPa) to the underdrive clutch pack.
21. Apply 30 psi (206 kPa) to the underdrive hose on Tool 8391 and measure UD clutch clearance. Measure and record UD clutch pack measurement in four (4) places, 90° apart.
22. Take average of four measurements and compare with UD clutch pack clearance specification. Underdrive clutch pack clearance must be 0.94 - 1.50 mm (0.037 - 0.059 inch).
23. If necessary, select the proper reaction plate to achieve specifications.
Fig. 205 Install OD Clutch Pack:
24. Install the OD clutch pack (four fibers/three steels) (1) (Fig. 205).
Fig. 206 Install Waved Snap Ring:
25. Install OD reaction plate waved snap ring (1) (Fig. 206).
Fig. 207 OD/Reverse Reaction Plate:
26. Install the OD/Reverse reaction plate (1) with large step down (towards OD clutch pack) (Fig. 207).
Fig. 208 Install Flat Snap Ring:
27. Install OD reaction plate flat snap ring (3) (Fig. 208).
Fig. 209 Measure OD Clutch Pack Clearance:
28. Measure OD clutch pack clearance. Set up dial indicator (1) on top of the OD/Reverse reaction plate (2) (Fig. 209).
29. Zero dial indicator and apply 30 psi (206 kPa) air pressure to the overdrive clutch hose on Tool 8391. Measure and record OD clutch pack measurement in four (4) places, 90° apart.
30. Take average of four measurements and compare with OD clutch pack clearance specification. The overdrive (OD) clutch pack clearance is 1.07 - 3.25 mm (0.042 - 0.128 inch).
If not within specifications, the clutch is not assembled properly. There is no adjustment for the OD clutch clearance.
Fig. 210 Install Reverse Clutch Pack:
31. Install reverse clutch pack (two fibers/one steel) (1, 2) (Fig. 210).
Fig. 211 Install Reaction Plate:
32. Install reverse clutch reaction plate (1) with the flat side down towards reverse clutch (Fig. 211).
Fig. 212 Install Reverse Clutch Snap Ring:
33. Tap reaction plate (3) down to allow installation of the reverse clutch snap ring (1). Install reverse clutch snap ring (1) (Fig. 212).
Fig. 213 Pry Up Reaction Plate:
34. Pry up reverse reaction plate (4) to seat against snap ring (2) (Fig. 213).
Fig. 214 Measure Reverse Clutch Pack Clearance:
35. Set up a dial indicator (1) on the reverse clutch pack (2) (Fig. 214).
Fig. 215 Press Down on Reverse Clutch and Zero Indicator:
36. Using moderate pressure, press down and hold (near indicator) reverse clutch disc (2) with screwdriver or suitable tool and zero dial indicator (1) (Fig. 215). When releasing pressure, indicator should advance 0.005 - 0.010 inches as clutch pack relaxes.
37. Apply 30 psi (206 kPa) air pressure to the reverse clutch hose on Tool 8391. Measure and record reverse clutch pack measurement in four (4) places, 90° apart.
38. Take average of four measurements and compare with reverse clutch pack clearance specification. The reverse clutch pack clearance is 0.89 - 1.37 mm (0.035 - 0.054 inch). Select the proper reverse clutch snap ring to achieve specifications.
39. To complete the assembly, reverse clutch and overdrive clutch must be removed.
Fig. 216 Install No. 2 Needle Bearing:
40. Install the number 2 needle bearing (1) (Fig. 216).
Fig. 217 Install Underdrive Shaft Assembly:
41. Install the underdrive shaft assembly (1) (Fig. 217).
Fig. 218 Install No. 3 Thrust Washer:
42. Install the number 3 thrust washer (1) (Fig. 218) to the underdrive shaft assembly (2). Be sure five tabs are seated properly
Fig. 219 Install No. 3 Thrust Plate:
43. Install the number 3 thrust plate (3) to the bottom of the overdrive shaft assembly (1). Retain with petrolatum or transmission assembly gel (2) (Fig. 219).
Fig. 220 Install Overdrive Shaft Assembly:
44. Install the overdrive shaft assembly (1) (Fig. 220).
Fig. 221 Input Clutch Assembly:
45. Reinstall overdrive and reverse clutch (Fig. 221). Rechecking these clutch clearances is not necessary.