Overdrive/Direct Clutch Assembly Disassembly/Assembly

OVERDRIVE/DIRECT CLUTCH ASSEMBLY DISASSEMBLY/ASSEMBLY

Disassembly





1. Remove the input shaft snap ring.






2. Remove the input shaft.






3. Remove the O/D (4, 5, 6) clutch hub.






4. Remove the O/D (4, 5, 6) clutch hub, No. 2 thrust bearing.






5. Remove the O/D (4, 5, 6) clutch snap ring.






6. Remove the O/D (4, 5, 6) clutch pressure plate and clutch assembly.






7. Install Overdrive Clutch and Balance Piston Service Set and 2-6 Spring Compressor on the balance piston.






8. Using a press, compress the O/D (4, 5, 6) clutch return spring and remove the snap ring.






9. Remove the Overdrive Clutch and Balance Piston Service Set and 2-6 Spring Compressor.






10. Remove and discard the balance piston.






11. Remove the O/D (4, 5, 6) piston return spring.






12. Install the clutch support tower and the 3 bolts.

- Tighten to 12 Nm {1.2 kgf-m, 106 ft-lbf}.






13. Remove Input Shaft Support Seal Installer.






14. Install the No. 1 O/D/direct clutch assembly thrust bearing.






15. Position the No. 1 O/D/direct clutch assembly in the transaxle case.






16. Apply compressed air to the O/D (4, 5, 6) clutch piston port and remove the O/D (4, 5, 6) clutch piston.






17. Remove the O/D/direct clutch assembly from the transaxle case.






18. Remove the O/D (4, 5, 6) clutch piston seal from the O/D/direct clutch assembly.






19. Remove the 2 seals from the O/D (4, 5, 6) clutch piston.






20. Install Overdrive Clutch and Balance Piston Service Set and 2-6 Spring Compressor on the direct (3, 5, R) clutch cylinder. Using a press, compress the direct (3, 5, R) clutch piston return spring, and remove the snap ring.

CAUTION:Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.






21. Remove Overdrive Clutch and Balance Piston Service Set and 2-6 Spring Compressor.






22. Remove the direct (3, 5, R) clutch cylinder.






23. Remove and discard the direct (3, 5, R) clutch piston.






24. Remove the direct (3, 5, R) clutch piston return spring.

CAUTION:Note the position of the return spring for assembly. The flat side faces down.






25. Remove the direct (3, 5, R) clutch snap ring.
a. Slightly lift up on the direct (3, 5, R) clutch so that the snap ring floats freely.

b. Using a suitable tool, compress the snap ring.

c. Allow the direct (3, 5, R) clutch and pressure plate to drop so that the snap ring is out of the pressure plate groove.

d. Remove the snap ring.






26. Remove the direct (3, 5, R) clutch pressure plate, clutch pack and wave spring.






27. Remove and discard the 3 direct (3, 5, R) clutch piston seals.

Assembly

1. Clean and inspect the O/D/direct clutch assembly for damage or excessive wear and install new components as necessary.






2. Install new direct (3, 5, R) clutch piston seals and lubricate the seals with petroleum jelly.






3. Install the direct (3, 5, R) clutch wave spring.






4. Soak the direct (3, 5, R) clutch pack in clean automatic transmission fluid.






5. Install the direct (3, 5, R) clutch assembly and pressure plate.






6. Install the direct (3, 5, R) clutch snap ring.
a. Using a suitable tool, compress the snap ring.

b. Lift the direct (3, 5, R) clutch so that the snap ring is in the groove of the pressure plate.

c. Release the tension on the snap ring.






7. Install the direct (3, 5, R) clutch piston return spring.

NOTE:Install the direct (3, 5, R) clutch piston return spring with the flat side facing down.






8. Lubricate a new direct (3, 5, R) clutch piston with petroleum jelly and install the piston.






9. Install the direct (3, 5, R) clutch cylinder.






10. Install Overdrive Clutch and Balance Piston Service Set and 2-6 Spring Compressor on the direct (3, 5, R) clutch cylinder. Using a press, compress the direct (3, 5, R) clutch piston return spring, and install the snap ring.

CAUTION:Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.






11. Remove Overdrive Clutch and Balance Piston Service Set and 2-6 Spring Compressor.






12. Install 2 new seals on the O/D (4, 5, 6) clutch piston and lubricate the seals with petroleum jelly.






13. Install a new O/D (4, 5, 6) clutch piston clutch piston inner seal and lubricate the seal with petroleum jelly.






14. Position the O/D (4, 5, 6) clutch piston in place.






15. Using Overdrive Clutch and Balance Piston Service Set, install the O/D (4, 5, 6) clutch piston into the O/D/direct clutch assembly by hand.






16. Install the O/D (4, 5, 6) clutch piston return spring.

NOTE:Holes face up on the O/D (4, 5, 6) clutch piston return spring.






17. Lubricate the seals on a new balance piston and position the piston in place.






18. Install Overdrive Clutch and Balance Piston Service Set and 2-6 Spring Compressor on the balance piston.






19. Using a press, compress the O/D (4, 5, 6) clutch return spring and install the snap ring.






20. Remove the Overdrive Clutch and Balance Piston Service Set and 2-6 Spring Compressor.






21. Install the No. 2 thrust bearing.






22. Install the O/D (4, 5, 6) clutch hub.






23. Soak the O/D (4, 5, 6) clutch pack in clean automatic transaxle fluid.






24. Install the O/D (4, 5, 6) clutch pack.






25. Install the O/D (4, 5, 6) clutch pressure plate.






26. Install the O/D (4, 5, 6) clutch snap ring.






27. Install the input shaft.






28. While holding the input shaft in place, install the snap ring.






29. Position the O/D/direct clutch assembly in the transaxle case, install Dial Indicator Gauge With Holding Fixture or a suitable dial indicator and position the plunger on the O/D (4, 5, 6) clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the O/D (4, 5, 6) clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.950 mm (0.037 in) and 1.778 mm (0.07 in). If the clearance is out of range, check the O/D (4, 5, 6) clutch pack for correct installation. If the O/D (4, 5, 6) clutch pack is correctly installed, install a new O/D (4, 5, 6) clutch pack.






30. Position the plunger on one of the top direct (3, 5, R) clutch plate tabs. Apply 483 kPa (70 psi) of air pressure to the direct (3, 5, R) clutch piston port while recording the clutch pack clearance on Dial Indicator Gauge With Holding Fixture. The clearance should be between 0.412 mm (0.016 in) and 1.728 mm (0.068 in). If the clearance is out of range, check the direct (3, 5, R) clutch pack for correct installation. If the direct (3, 5, R) clutch pack is correctly installed, install a new direct (3, 5, R) clutch pack.






31. Remove Dial Indicator Gauge With Holding Fixture, O/D/direct clutch assembly and the No. 1 O/D/direct clutch assembly thrust bearing.