Assembly - Input Clutch: Assembly

Use petrolatum on all seals to ease assembly of components.

Fig 1: Install Input Shaft

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1. Using an arbor press (2), install input shaft (1) to input shaft hub (2). See Fig 1.
   Fig 2: Install Input Shaft Snap Ring

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   1 - INPUT SHAFT

   2 - SCREWDRIVER (DO NOT SCRATCH BEARING SURFACE)

   3 - SNAP RING

   4 - O-RINGS

   5 - SEALS

2. Install input shaft snap ring (3). See Fig 2.
   Fig 3: Return Spring and Snap Ring

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   1 - OD/REVERSE PISTON

   2 - RETURN SPRING

   3 - SNAP RING

   4 - O-RING

3. Position the OD/Reverse piston return spring (2) and snap ring (3) onto the OD/Reverse piston (1). See Fig 3.
   Fig 4: Install Snap Ring

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   1 - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST ENOUGH TO REMOVE OR INSTALL SNAP RING)

   2 - SCREWDRIVER

   3 - SNAP RING

   4 - SPECIAL TOOL 6057

   5 - OD/REVERSE PISTON

   6 - RETURN SPRING

4. Using an arbor press (1) and Tool 6057 (4), install the OD/Reverse piston return spring (6) and snap ring (3). See Fig 4.
   Fig 5: Install OD/Reverse Piston

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   1 - PUSH DOWN TO INSTALL OVERDRIVE/REVERSE PISTON

   2 - INPUT CLUTCHES RETAINER

5. Install the OD/Reverse piston (1) assembly to the input clutch retainer (2). See Fig 5.
   Fig 6: Install Input Shaft Hub Assembly

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   1 - PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY (ROTATE TO ALIGN SPLINES)

   2 - OD/REV. PISTON

6. Install the input hub/shaft assembly (1) to the OD/Reverse piston/clutch retainer assembly (2). See Fig 6.
   Fig 7: Install Input Hub Tapered Snap Ring

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   1 - INPUT SHAFT

   2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN CAVITY)

   3 - SNAP RING PLIERS

7. Install input hub tapered snap ring (2). See Fig 7. Make sure snap ring is fully seated. 
   Fig 8: Underdrive Clutch Piston

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   1 - PISTON

8. Install the UD clutch piston (1). See Fig 8.
   Fig 9: Seal Compressor Special Tool 5067

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   1 - PISTON RETURN SPRING

   2 - SPECIAL TOOL 5067

   3 - INPUT CLUTCH RETAINER

9. Install UD piston return spring (1) and Tool 5067 (2). See Fig 9.
   Fig 10: UD Return Spring and Retainer

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   1 - UNDERDRIVE SPRING RETAINER

   2 - SNAP RING

   3 - SEAL

   4 - PISTON RETURN SPRING

10. Position the UD spring retainer (1) and snap ring (2) on the piston return spring (4). See Fig 10.
    Fig 11: Install UD Spring Retainer and Snap Ring

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    1 - ARBOR PRESS RAM

    2 - SNAP RING PLIERS

    3 - SNAP RING

    4 - OD/REVERSE PISTON

    5 - TOOL 5067

    6 - TOOL 5059A

    CAUTION: Compress return spring just enough to install snap ring.
11. Using Tool 5059A (6) and an arbor press (1), install the UD spring retainer and snap ring (3). See Fig 11.
    Fig 12: Underdrive Clutch Pack

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    1 - CLUTCH PLATE

    2 - ONE UD CLUTCH DISC

    3 - CLUTCH DISC

12. Install the UD clutch pack (four fibers/four steels) (1, 3). See Fig 12. Leave the top disc (2) out until after the snap ring is installed.
    Fig 13: UD Clutch Flat Snap Ring

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    1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING

    2 - SCREWDRIVER

13. Install the UD clutch flat snap ring (1). See Fig 13.
    Fig 14: Install Last UD Clutch Disc

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    1 - ONE UNDERDRIVE CLUTCH DISC

14. Install the last UD clutch disc (1). See Fig 14.
    Fig 15: OD/UD Reaction Plate

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    1 - OD/UD CLUTCH REACTION PLATE (STEP SIDE DOWN)

15. Install the OD/UD clutch reaction plate (1). See Fig 15. The OD/UD clutches reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up.
    Fig 16: Tapered Snap Ring

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    1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING

    2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)

    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.
16. Install the UD/OD tapered snap ring (1). See Fig 16.
    Fig 17: Seating Tapered Snap Ring

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    1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING

    2 - SCREWDRIVER

17. Seat tapered snap ring (1) to ensure proper installation. See Fig 17.
    Fig 18: Input Clutch Assembly on Pressure Fixture Tool - 8391

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    1 - INPUT CLUTCH ASSEMBLY

    2 - INPUT CLUTCH PRESSURE FIXTURE - 8391

18. Install input clutch assembly (1) to the Input Clutch Pressure Fixture 8391 (2). See Fig 18.
    Fig 19: Set Up Dial Indicator to Measure UD Clutch Clearance

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    1 - DIAL INDICATOR

    2 - UNDERDRIVE CLUTCH

19. Set up dial indicator (1) on the UD clutch pack (2). See Fig 19.
    Fig 20: Press Down on UD Clutch Pack and Zero Dial Indicator

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    1 - DIAL INDICATOR

    2 - UNDERDRIVE CLUTCH

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). See Fig 20. 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 in.). 
23. If necessary, select the proper reaction plate to achieve specifications.
    Fig 21: Install OD Clutch Pack

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    1 - OVERDRIVE CLUTCH PACK

24. Install the OD clutch pack (four fibers/three steels) (1). See Fig 21.
    Fig 22: Install Waved Snap Ring

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    1 - OVERDRIVE REACTION PLATE WAVED SNAP RING

    2 - SCREWDRIVER

25. Install OD reaction plate waved snap ring (1). See Fig 22.
    Fig 23: OD/Reverse Reaction Plate

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    1 - OVERDRIVE/REVERSE PRESSURE PLATE

    2 - (STEP SIDE DOWN)

26. Install the OD/Reverse reaction plate (1) with large step down (towards OD clutch pack). See Fig 23.
    Fig 24: Install Flat Snap Ring

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    1 - ARBOR PRESS RAM

    2 - TOOL 5059A

    3 - FLAT SNAP RING

27. Install OD reaction plate flat snap ring (3). See Fig 24.
    Fig 25: Measure OD Clutch Pack Clearance

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    1 - DIAL INDICATOR

    2 - OD/REVERSE PRESSURE PLATE

28. Measure OD clutch pack clearance. Set up dial indicator (1) on top of the OD/Reverse reaction plate (2). See Fig 25.
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 in.). 

    If not within specifications, the clutch is not assembled properly. There is no adjustment for the OD clutch clearance.

    Fig 26: Install Reverse Clutch Pack

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    1 - REVERSE CLUTCH PLATE

    2 - REVERSE CLUTCH DISCS

31. Install reverse clutch pack (two fibers/one steel) (1, 2). See Fig 26.
    Fig 27: Install Reaction Plate

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    1 - REVERSE CLUTCH REACTION PLATE (FLAT SIDE DOWN)

32. Install reverse clutch reaction plate (1) with the flat side down towards reverse clutch. See Fig 27.
    Fig 28: Install Reverse Clutch Snap Ring

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    1 - REVERSE CLUTCH SNAP RING (SELECT)

    2 - SCREWDRIVER

    3 - REVERSE CLUTCH REACTION PLATE

33. Tap reaction plate (3) down to allow installation of the reverse clutch snap ring (1). Install reverse clutch snap ring (1). See Fig 28.
    Fig 29: Pry Up Reaction Plate

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    1 - SCREWDRIVER

    2 - SNAP RING

    3 - SCREWDRIVER

    4 - MUST RAISE REVERSE REACTION PLATE TO RAISE SNAP RING

34. Pry up reverse reaction plate (4) to seat against snap ring (2). See Fig 29.
    Fig 30: Measure Reverse Clutch Pack Clearance

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    1 - DIAL INDICATOR

    2 - REVERSE CLUTCH

35. Set up a dial indicator (1) on the reverse clutch pack (2). See Fig 30.
    Fig 31: Press Down on Reverse Clutch and Zero Indicator

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    1 - DIAL INDICATOR

    2 - REVERSE CLUTCH

36. Using moderate pressure, press down and hold (near indicator) reverse clutch disc (2) with screwdriver or suitable tool and zero dial indicator (1). See Fig 31. 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 in.).  Select the proper reverse clutch snap ring to achieve specifications.
39. To complete the assembly, reverse clutch and overdrive clutch must be removed.
    Fig 32: Install No. 2 Needle Bearing

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    1 - #2 NEEDLE BEARING (NOTE 3 SMALL TABS)

    2 - TABS UP

40. Install the number 2 needle bearing (1). See Fig 32.
    Fig 33: Install Underdrive Shaft Assembly

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    1 - UNDERDRIVE SHAFT ASSEMBLY

    2 - #2 NEEDLE BEARING

41. Install the underdrive shaft assembly (1). See Fig 33.
    Fig 34: Install No. 3 Thrust Washer

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    1 - #3 THRUST WASHER (NOTE 5 TABS)

    2 - UNDERDRIVE SHAFT ASSEMBLY

42. Install the number 3 thrust washer (1) to the underdrive shaft assembly (2). See Fig 34. Be sure five tabs are seated properly.
    Fig 35: Install No. 3 Thrust Plate

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    1 - OVERDRIVE SHAFT ASSEMBLY

    2 - DABS OF PETROLATUM (FOR RETENTION)

    3 - #3 THRUST PLATE (NOTE 3 TABS)

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). See Fig 35.
    Fig 36: Install Overdrive Shaft Assembly

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    1 - OVERDRIVE SHAFT ASSEMBLY

    2 - #3 THRUST PLATE

    3 - #3 THRUST WASHER

44. Install the overdrive shaft assembly (1). See Fig 36.
    Fig 37: Input Clutch Assembly

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    1 - INPUT CLUTCH ASSEMBLY

    2 - OVERDRIVE SHAFT ASSEMBLY

45. Reinstall overdrive and reverse clutch. See Fig 37. Rechecking these clutch clearances is not necessary.