Assembly, Input Clutch: Assembly

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1 - INPUT SHAFT

2 - ARBOR PRESS

3 - INPUT SHAFT HUB ASSEMBLY

Use petrolatum on all seals to ease assembly of components.

Using an arbor press (2), install input shaft (1) to input shaft hub (3).

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1 - INPUT SHAFT

2 - SCREWDRIVER (DO NOT SCRATCH BEARING SURFACE)

3 - SNAP RING

4 - O-RINGS

5 - SEALS

Install input shaft snap ring (3).

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1 - OD/REVERSE PISTON

2 - RETURN SPRING

3 - SNAP RING

4 - O-RING

Place OD/Reverse piston (1) return spring (2) and snap ring (3) in position.

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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 - Disk 6057

5 - OD/REVERSE PISTON

6 - RETURN SPRING

Using an arbor press (1) and spring compressor disc (special tool #6057, Disc, Spring Compressor) (4), install OD/Reverse piston (5), return spring (6), and snap ring (3).

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1 - PUSH DOWN TO INSTALL OVERDRIVE/REVERSE PISTON

2 - INPUT CLUTCHES RETAINER

Install the OD/Reverse piston assembly (1) to the input clutch retainer (2).

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

2 - OD/REV. PISTON

Install the input hub/shaft assembly (1) (rotate to align splines) to the OD/Reverse piston/clutch retainer assembly (2).

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1 - SNAP RING (INPUT SHAFT)

2 - SNAP RING

3 - CLUTCH RETAINER

4 - SEAL, OUTER

5 - SEAL, INNER

6 - OD/REVERSE PISTON

7 - SEAL, INPUT SHAFT

8 - SHAFT, INPUT

9 - HUB

10 - SEAL

11 - SNAP RING

12 - BELLEVILLE SPRING

Refer to the exploded view as necessary when performing the following steps.

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1 - INPUT SHAFT

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

3 - SNAP RING PLIERS

Install input hub tapered snap ring (2) (tapered side up with tabs in cavity).

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1 - PISTON

Install UD clutch piston (1).

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1 - PISTON RETURN SPRING

2 - INSTALLER 5067

3 - INPUT SHAFT CLUTCHES RETAINER ASSEMBLY

Install UD piston return spring (1) and use seal installer (special tool #5067, Installer, Seal) (2) to install a NEW outer seal.

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1 - SNAP RING

2 - SPRING RETAINER

3 - SPRING

4 - UD CLUTCH PISTON

5 - SEAL, OUTER

6 - SEAL, INNER

7 - INPUT CLUTCH ASSEMBLY

Refer to the exploded view as necessary when performing the following steps.

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1 - UNDERDRIVE SPRING RETAINER

2 - SNAP RING

3 - SEAL

4 - PISTON RETURN SPRING

Place the UD spring retainer (1) and snap ring (2) in position.

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1 - ARBOR PRESS RAM

2 - SNAP RING PLIERS

3 - SNAP RING

4 - OD/REVERSE PISTON

5 - INSTALLER 5067

6 - COMPRESSOR 5059-A

Using spring compressor (special tool #5059-A, Compressor, Spring) (6) and an arbor press (1), install the UD spring retainer and snap ring (3). Compress just enough to install snap ring (3).

CAUTION:

Compress return spring just enough to install snap ring.

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1 - CLUTCH PLATE

2 - ONE UD CLUTCH DISC

3 - CLUTCH DISC

Install the UD clutch pack (1, 3). Leave out upper disc (2), until snap ring is installed.

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1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING

2 - SCREWDRIVER
Install the UD clutch flat snap ring (1).

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1 - ONE UNDERDRIVE CLUTCH DISC
Install the last UD clutch disc (1).

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

Place the OD/UD clutch reaction plate (1) and snap ring into position. The OD/UD clutches reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up.

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1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING

2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)

Install the snap ring (1) using a screwdriver (2).

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.

NOTE:

Do not reuse tapered snap ring.

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1 - SNAP RING (TAPERED)

2 - OD/UD REACTION PLATE

3 - CLUTCH DISC

4 - SNAP RING (FLAT)

5 - CLUTCH PLATE

6 - INPUT CLUTCH ASSEMBLY

Refer to the exploded view as necessary when performing the following steps.

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1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING

2 - SCREWDRIVER

NOTE:

Do not reuse tapered snap ring.

Seat tapered snap ring (1) to ensure proper installation.

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1 - INPUT CLUTCH ASSEMBLY

2 - INPUT CLUTCH PRESSURE FIXTURE 8391
Install input clutch assembly (1) to the pressure test fixture (special tool #8391, Fixture, Pressure Test) (2).

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1 - DIAL INDICATOR

2 - UNDERDRIVE CLUTCH
Set up dial indicator (1) on the UD clutch pack (2).

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1 - DIAL INDICATOR

2 - UNDERDRIVE CLUTCH
Using moderate pressure, press down and hold (near indicator) the UD clutch pack (2) with screwdriver or suitable tool and zero dial the indicator. When releasing pressure on clutch pack, indicator reading should advance (0.005-0.010 in.).
CAUTION:
Do not apply more than 30 psi (206 kPa) to the underdrive clutch pack.
Apply 30 psi (206 kPa) to the underdrive hose on pressure test fixture (special tool #8391, Fixture, Pressure Test) and measure UD clutch clearance. Measure and record UD clutch pack measurement in four places, 90° apart.
Take average of four measurements and compare with UD clutch pack (2) clearance specification. Underdrive clutch pack clearance must be 0.91-1.47 mm (0.036 - 0.058 in.).

If necessary, select the proper reaction plate to achieve specifications:

UNDERDRIVE REACTION PLATE THICKNESS
4659939AB	5.837-5.937 mm (0.230-0.234 in.)
4659940AB	6.147-6.248 mm (0.242-0.246 in.)
4659941AB	6.457-6.557 mm (0.254-0.258 in.)

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1 - OVERDRIVE CLUTCH PACK

Install the OD clutch pack (four frictions/three steels) (1).

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1 - OVERDRIVE PRESSURE PLATE WAVED SNAP RING

2 - SCREWDRIVER
Install OD pressure plate waved snap ring (1).

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1 - OVERDRIVE/REVERSE PRESSURE PLATE

2 - (STEP SIDE DOWN)

Install the OD/Reverse pressure plate (1) with large step down (towards OD clutch pack) (2).

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1 - SNAP RING

2 - OD/REVERSE PRESSURE PLATE

3 - SNAP RING (WAVE)

4 - CLUTCH DISC (4)

5 - CLUTCH STEEL (3)

6 - INPUT CLUTCH ASSEMBLY

Refer to the exploded view as necessary when performing the following steps.

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1 - ARBOR PRESS RAM

2 - COMPRESSOR 5059-A

3 - FLAT SNAP RING

Using spring compressor (special tool #5059-A, Compressor, Spring) (2) and an arbor press, install OD pressure plate flat snap ring (3).

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1 - DIAL INDICATOR

2 - OD/REVERSE REACTION PLATE
Measure OD clutch pack clearance. Set up dial indicator (1) on top of the OD/Reverse pressure plate (2).
Zero dial indicator and apply 30 psi (206 kPa) air pressure to the overdrive clutch hose on Tool (special tool #8391, Fixture, Pressure Test). Measure and record OD clutch pack measurement in four (4) places, 90° apart.
Take average of four measurements and compare with OD clutch pack clearance specification. The overdrive (OD) clutch pack clearance is 0.491-2.345 mm 0.019-.092 in.
If not within specifications, the clutch is not assembled properly. There is no adjustment for the OD clutch clearance.

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1 - REVERSE CLUTCH PLATE

2 - REVERSE CLUTCH DISCS
Install reverse clutch pack (two frictions/one steel) (1, 2).

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1 - REVERSE CLUTCH REACTION PLATE (FLAT SIDE DOWN)

Install reverse clutch reaction plate (1) with the flat side down towards reverse clutch.

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1 - SNAP RING

2 - REACTION PLATE

3 - CLUTCH DISC (2)

4 - CLUTCH PLATE (1)

5 - INPUT CLUTCH ASSEMBLY

Refer to the exploded view as necessary when performing the following steps.

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1 - REVERSE CLUTCH SNAP RING (SELECT)

2 - SCREWDRIVER

3 - REVERSE CLUTCH REACTION PLATE

Tap reaction plate (3) down to allow installation of the reverse clutch snap ring (1). Install reverse clutch snap ring (1).

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1 - SCREWDRIVER

2 - SNAP RING

3 - SCREWDRIVER

4 - MUST RAISE REVERSE REACTION PLATE TO RAISE SNAP RING

Pry up reverse reaction plate (4) to seat against snap ring (2).

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1 - DIAL INDICATOR

2 - REVERSE CLUTCH
Set up a dial indicator (1) on the reverse clutch pack (2).

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1 - DIAL INDICATOR

2 - REVERSE CLUTCH
Using moderate pressure, press down and hold (near indicator) reverse clutch disc (2) with screwdriver or suitable tool and zero dial indicator (1). When releasing pressure, indicator should advance (0.005-0.010 in.) as clutch pack relaxes.
Apply 30 psi (206 kPa) air pressure to the reverse clutch hose on Input Clutch Pressure Fixture (special tool #8391, Fixture, Pressure Test). Measure and record reverse clutch pack measurement in four places, 90° apart.

Take average of four measurements and compare with reverse clutch pack clearance specification. The reverse clutch pack clearance is 0.76-1.245 mm (0.030-0.049 in.). Select the proper reverse clutch snap ring to achieve specifications:

REVERSE CLUTCH SNAP RING THICKNESS
4377195	1.53-1.58 mm (0.060-0.062 in.)
4412871	1.77-1.83 mm (0.070-0.072 in.)
4412872	2.02-2.07 mm (0.080-0.082 in.)
4412873	2.27-2.32 mm (0.090-0.091 in.)

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

2 - TABS UP

NOTE:

The No. 2 bearing is a light press fit into the clutch hub. There are 5 tabs with dimples that can be pressed in by hand.

To complete the assembly, reverse clutch and overdrive clutch must be removed.
Install the number two needle bearing (1).

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1 - UNDERDRIVE SHAFT ASSEMBLY

2 - #2 NEEDLE BEARING
Install the underdrive shaft assembly (1).

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1 - #3 THRUST WASHER (NOTE 5 TABS)

2 - UNDERDRIVE SHAFT ASSEMBLY

Install the number three thrust washer (1) to the underdrive shaft assembly (2). Be sure five tabs are seated properly.

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1 - OVERDRIVE SHAFT ASSEMBLY

2 - DABS OF PETROLATUM (FOR RETENTION)

3 - #3 THRUST PLATE (NOTE 3 TABS)

Install the number three thrust plate (3) (note 3 tabs) to the bottom of the overdrive shaft assembly (1). Retain with petrolatum or transmission assembly gel (2).

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1 - OVERDRIVE SHAFT

2 - #3 THRUST PLATE (3 TABS)

3 - #3 THRUST WASHER (5 TABS)

4 - UNDERDRIVE SHAFT

5 - #2 NEEDLE BEARING (3 TABS)

6 - INPUT CLUTCH ASSEMBLY

Refer to the exploded view as necessary when performing the following steps.

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1 - OVERDRIVE SHAFT ASSEMBLY

2 - #3 THRUST PLATE

3 - #3 THRUST WASHER

Install the overdrive shaft assembly (1).
Reinstall overdrive and reverse clutch as shown in the figure. Rechecking these clutch clearances is not necessary.