INTERMEDIATE BRAKE AND DIRECT CLUTCH DRUM COMPONENT DISASSEMBLY/ASSEMBLY

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Intermediate Brake and Direct Clutch Drum Component

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1	Intermediate brake drum
2	Direct clutch piston outer seal ring
3	Direct clutch piston inner seal ring
4	Direct clutch piston
5	Direct clutch piston spring (20 required)
6	Direct clutch piston spring retainer
7	Retaining ring
8	Direct clutch external spline plate (steel)
9	Direct clutch internal spline plates (friction)
10	Direct clutch pressure plate
11	Retaining ring (select fit)

Disassembly

Caution

•  The retaining ring is a select fit. See assembly procedure if installation of new ring or clutch pack is required.

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

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(1)  Remove the retaining ring.

(2)  Remove the direct clutch pressure plate.

Caution

•  Clutch plates are directional. Note the direction of the grooves for installation.

2.  Remove the direct clutch disc pack.

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•  Inspect and install new friction plates if worn, damaged or overheated.

•  Measure and record the thickness of the steel plates for assembly.

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 SST or damage to the spring retainer may occur.

3.  Using the SST, remove the retaining ring.

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4.  Relieve the direct clutch spring tension and remove the SST.

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

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(1)  Remove the direct clutch piston spring retainer.

(2)  Remove the direct clutch piston springs.

Warning

•  Air pressure must not exceed 138 kPa {1.4 kgf/cm², 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.

6.  Using compressed air, remove the direct clutch piston from the intermediate brake drum.

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•  Apply air pressure to the hole in the drum while blocking the other hole with a finger.

7.  Remove and discard the direct clutch piston inner and outer seal.

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(1)  Remove and discard the direct clutch piston inner seal ring.

(2)  Remove and discard the direct clutch piston outer seal ring.

•  Clean the components as necessary.

Assembly

Caution

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

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

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Note

•  Use new seals to help prevent seal failures.

Caution

•  Lubricate the direct clutch piston inner and outer seal rings with clean ATF.

2.  Inspect the clutch components for damage or wear. Install new components as necessary.

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•  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.

•  Verify the check ball is free to move.

Caution

•  Care must be taken to prevent damage to the seals during installation.

3.  Install the direct clutch piston.

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•  Lubricate the seals with transmission fluid before installing.

4.  Install the direct clutch piston springs and the retainer.

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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 SST or damage to the spring retainer may occur.

5.  Using the SST, install the retaining ring.

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6.  Relieve the direct clutch spring tension and remove the SST.

Caution

•  The direct clutch friction plates are directional and must be installed with grooves pointing clockwise (ID to OD) and the word TOP facing up.

•  If new plates are used, they should be soaked in clean ATF before assembly.

7.  When installing friction plates, the word TOP should face up. If reusing plates, grooves must be installed clockwise. Install the direct clutch disc pack.

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8.  Install the steel clutch plates and friction clutch plates in alternating order starting with a steel clutch plate.

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Caution

•  The retaining ring is a select fit.

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

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Warning

•  Air pressure must not exceed 138 kPa {1.4 kgf/cm², 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.

Note

•  The direct clutch piston must apply with air pressure and release when air is removed.

10.  Air check the assembly.

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•  Apply air pressure to the hole in the drum while blocking the other hole with a finger.

11.  Push down on the direct clutch disc pack and check the gap between the direct clutch retaining ring and the direct clutch pressure plate with a feeler gauge.

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•  If the specifications do not match, use a select fit direct clutch retaining ring to match specifications and verify with a feeler gauge.

Direct clutch clearance

Standard: 1.3—2.0 mm {0.051—0.079 in}

Retaining ring size for direct clutch clearance