1ST Clutch, 1ST Drive Gear and 1ST Driven Gear (on-Vehicle)

1ST CLUTCH, 1ST DRIVE GEAR AND 1ST DRIVEN GEAR (ON-VEHICLE)

TOOLS REQUIRED
- SA9119T Input Shaft Holding Tool

REMOVAL





1. Remove end cover.
2. Install the Input Shaft Holding Tool SA9119T.





3. Remove the input shaft nut.
4. Remove holding tool, and remove the output shaft nut.





5. Remove 1st clutch housing and 1st drive gear from the input shaft.





6. Remove 1st driven gear, sprag clutch, and thrust washer from the output shaft.

INSTALLATION





1. Install 1st driven gear and sprag assembly on output shaft.
2. Install 1st driven gear thrust washer on output shaft.

NOTICE: Use a new nut due to insufficient torque retention of old nut. Clean shaft threads with wire brush. When tightening and torquing this nut it must be done with a hand wrench or torque wrench. Using a power tool will generate excess heat in the fastener causing an incorrect torque.

3. Hand start the new output shaft clamp nut. Torque nut with a torque wrench.
Torque:
Output Shaft Clamp Nut: 150 Nm (111 ft. lbs.)
4. Lay 1st clutch housing on flat surface.

NOTICE: Make sure tabs on 1st drive gear thrust washer line up with slots on the 1st clutch housing assembly hub or damage to the 1st drive gear thrust washer will occur.

IMPORTANT: Chamfer side goes toward the clutch housing and flat side goes toward 1st gear.





5. Apply a generous amount of petroleum jelly to hold the 1st drive gear thrust washer in place and install the 1st drive gear thrust washer on the 1st clutch housing assembly hub.
6. Install thrust bearing with rollers (down) toward 1st drive gear thrust washer.
7. Install 1st clutch, clutch (needle) bearing.
8. Install 1st drive gear and hub assembly into 1st clutch housing assembly by twisting the gear to align the gear hub with the clutch tangs.
9. When installing the 1st drive gear and hub assembly into the clutch pack, rotate the gear and hub assembly back and forth to align the clutch plates. If you are not sure that all of the clutch plates have been engaged, lift the gear out of the clutch housing and verify that all clutch tangs are aligned.
10. Install 1st drive gear thrust washer.

IMPORTANT: If assembly is not held together, the gear hub may slide out of the clutch housing which may allow the 1st gear thrust washer to move out of location or allow clutch plates to be pinched when the input shaft nut is torqued.





11. Hold the 1st drive gear and hub assembly together and install on the input shaft.
12. Install 1st drive gear and hub assembly, and 1st clutch housing assembly on the input shaft.





13. Install the Input Shaft Holding Tool SA91l9T.

NOTICE: Use a new nut due to insufficient torque retention of old nut. Clean shaft threads with a wire brush. When tightening and torquing this nut it must be done quickly with a hand wrench or torque wrench. If not done quickly, the thread locking material used on the new nut will cure in a short time resulting in an incorrect torque. Using a power tool will generate excess heat in the fastener causing a incorrect torque.

14. Hand start the new input shaft clamp nut. Torque nut with a torque wrench.
Torque:
Input Shaft Clamp Nut: 150 Nm (111 ft. lbs.)
15. After input and output shaft nuts have been installed, verify proper operation.
15.1 Engage park pawl.
15.2 Rotate input shaft by turning the 1st clutch housing in both directions. The clutch housing should turn freely in both directions.
^ If input shaft turns freely in only one direction, the 1st clutch is binding. Disassemble 1st gear and clutch assembly and follow the steps.
^ If input shaft will not turn freely in either direction, 2nd, 3rd or 4th clutch is binding, Refer to proper repair procedure.
^ If the input shaft turns freely in both directions, refer to next step.