Direct Clutch Drum Assembly

Direct Clutch Drum Assembly





Special Tool(s)









Direct Clutch

Disassembly





1. Remove the direct clutch retaining ring and the direct clutch pressure plate.
1 Remove the direct clutch retaining ring.
2 Remove the direct clutch pressure plate.





2. Remove the direct clutch disc pack.
^ Inspect and install new friction plates if worn, damaged, or overheated.





3. WARNING: After removing the retaining ring, use care when releasing the pressure on the springs. Failure to follow these instructions may result in personal injury.

CAUTION: Do not fully compress the special tool or damage to the spring retainer may occur.

Using the special tool, remove the direct clutch piston retaining ring.
4. Relieve the direct clutch spring tension and remove the special tool.





5. Remove the direct clutch piston spring retainer and the direct clutch piston springs.
1 Remove the direct clutch piston spring retainer.
2 Remove the direct clutch piston springs.





6. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air, and make sure the drum is facing down as shown. Failure to follow these instructions may result in personal injury.

Using compressed air, remove the direct clutch piston from the direct clutch drum.
^ Apply air pressure to the hole in the drum while blocking the other hole with a finger.





7. Remove the direct clutch piston inner and outer seal.
1 Remove the direct clutch piston inner seal.
2 Remove the direct clutch piston outer seal.
^ Clean and install new components as necessary.

Assembly
1. Inspect the clutch components for damage or wear. Install new components as necessary.
^ Inspect the drum surface for damage.
^ Inspect the clutch piston bore, and piston.
^ Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
^ Inspect the clutch plates for damage.
^ Inspect the clutch springs.





2. CAUTION: The lip seals must be positioned as shown. Care must be taken to prevent rollover of the lip seal.

NOTE: Use new seals to help prevent seal failures.

Install the new direct clutch piston inner seal and the direct clutch piston outer seal.





3. Verify the check ball is free to move.





4. CAUTION: Care must be taken to prevent damage to the seals during installation.

Using the special tool, install the direct clutch piston.





5. Install the direct clutch piston springs and the retainer.
6. Relieve the direct clutch spring tension and remove the special tool.





7. WARNING: After removing the retaining ring, use care when releasing the pressure on the springs. Failure to follow these instructions may result in personal injury.

CAUTION: Do not fully compress the special tool or damage to the spring retainer may occur.

Using the special tool, install the direct clutch piston retaining ring.





8. CAUTION: The direct clutch friction plates are directional and must be installed correctly. Alternate the internally spliced (clockwise) and the externally splined (counterclockwise) clutch plates.

CAUTION: If new plates are used, they should be soaked in clean automatic transmission fluid for at least 30 minutes before assembly.

When installing friction plates, alternate the internally splined (clockwise) and the externally splined (counterclockwise) clutch plates. Install the direct clutch disc pack.





9. Install the friction plates alternating the internally splined (clockwise) and the externally splined (counterclockwise) clutch plates starting with an externally splined (counterclockwise) clutch plate.





10. CAUTION: The retaining ring is a select fit.

Install the direct clutch pressure plate using the original direct clutch retaining ring.





11. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air, and make sure drum is facing down as shown. Failure to follow these instructions may result in personal injury.

Air check the assembly.
^ Apply air pressure to the hole in the drum while blocking the other hole with a finger.





12. Push down on direct clutch disc pack and check gap between the direct clutch retaining ring and the direct clutch pressure plate with a feeler gauge.
^ If specifications do not match use a select fit direct clutch retaining ring to match specifications and verify with a feeler gauge.