Input Clutch Assembly: Assembly

Use petrolatum on all seals to ease assembly of components.

1. Using an arbor press, install input shaft to input shaft hub (Fig 1).
   Fig 1: Installing Input Shaft

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2. Install input shaft snap ring (Fig 2).
   Fig 2: Installing Input Shaft Snap Ring

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3. Using an arbor press and Tool 6057, Install OD/Reverse piston return spring and snap ring (Fig 3) (Fig 4).
   Fig 3: Identifying Return Spring and Snap Ring

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   Fig 4: Installing Snap Ring

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4. Install the OD/Reverse piston assembly to the input clutch retainer as shown in (Fig 5).
   Fig 5: Installing OD/Reverse Piston

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5. Install the input hub/shaft assy. to the OD/Reverse piston/clutch retainer assy. (Fig 6).
   Fig 6: Installing Input Shaft Hub Assembly

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6. Install input hub tapered snap ring (Fig 7).
   Fig 7: Installing Input Hub Tapered Snap Ring

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7. Install UD clutch piston (Fig 8).
   Fig 8: Underdrive Clutch Piston

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8. Install UD piston return spring and Tool 5067 as shown in (Fig 9).
   Fig 9: Identifying Seal Compressor Special Tool 5067

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9. Using Tool 5059A and an arbor press, Install the UD spring retainer and snap ring. (Fig 10) (Fig 11) Compress just enough to install snap ring.
   CAUTION: Compress return spring just enough to install snap ring.
   Fig 10: Installing UD Return Spring And Retainer

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   Fig 11: Installing UD Spring Retainer And Snap Ring

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10. Install the UD clutch pack. Leave out upper disc, until snap ring is installed (Fig 12).
    Fig 12: Installing Underdrive Clutch Pack

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11. Install the UD clutch flat snap ring (Fig 13).
    Fig 13: Installing UD Clutch Flat Snap Ring

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12. Install the last UD clutch disc (Fig 14).
    Fig 14: Installing Last UD Clutch Disc

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13. Install the OD/UD clutch reaction plate and snap ring (Fig 15) (Fig 16). The OD/UD clutches reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up.
    Fig 15: Installing OD/UD Reaction Plate

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    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.
    Fig 16: Identifying Tapered Snap Ring

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14. Seat tapered snap ring to ensure proper installation (Fig 17).
    Fig 17: Seating Tapered Snap Ring

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15. Install input clutch assembly to the Input Clutch Pressure Fixture-Tool 8391 (Fig 18).
    Fig 18: Installing Input Clutch Assembly On Pressure Fixture Tool 8391

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16. Set up dial indicator on the UD clutch pack as shown in (Fig 19).
    Fig 19: Set Up Dial Indicator to Measure UD Clutch Clearance

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17. Using moderate pressure, press down and hold (near indicator) the UD clutch pack with screwdriver or suitable tool and zero dial indicator (Fig 20). When releasing pressure on clutch pack, indicator reading should advance 0.005-0.010.
    CAUTION: Do not apply more than 30 psi (206 kPa) to the underdrive clutch pack.
    Fig 20: Press Down on UD Clutch Pack and Zero Dial Indicator

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18. 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.
19. 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.). 
20. If necessary, select the proper reaction plate to achieve specifications:
    UNDERDRIVE REACTION PLATE THICKNESS SPECIFICATION
    
    

    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.)

21. Install the OD clutch pack (four frictions/three steels) (Fig 21).
    Fig 21: Installing OD Clutch Pack

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22. Install OD pressure plate waved snap ring (Fig 22).
    Fig 22: Installing Waved Snap Ring

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23. Install the OD/Reverse pressure plate with large step down (towards OD clutch pack) (Fig 23).
    Fig 23: Installing OD/Reverse Pressure Plate

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24. Install OD pressure plate flat snap ring (Fig 24).
    Fig 24: Installing Flat Snap Ring

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25. Measure OD clutch pack clearance. Set up dial indicator on top of the OD/Reverse pressure plate as shown in (Fig 25).
    Fig 25: Measuring OD Clutch Pack Clearance

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26. 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.
27. 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.

28. Install reverse clutch pack (two frictions/one steel) (Fig 26).
    Fig 26: Installing Reverse Clutch Pack

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29. Install reverse clutch reaction plate with the flat side down towards reverse clutch (Fig 27).
    Fig 27: Installing Reaction Plate

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30. Tap reaction plate down to allow installation of the reverse clutch snap ring. Install reverse clutch snap ring (Fig 28).
    Fig 28: Installing Reverse Clutch Snap Ring

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31. Pry up reverse reaction plate to seat against snap ring (Fig 29).
    Fig 29: Prying Up Reaction Plate to Seat Against Snap Ring

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32. Set up a dial indicator on the reverse clutch pack as shown in (Fig 30).
    Fig 30: Measuring Reverse Clutch Pack Clearance

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33. Using moderate pressure, press down and hold (near indicator) reverse clutch disc with screwdriver or suitable tool and zero dial indicator (Fig 31). When releasing pressure, indicator should advance 0.005-0.010. as clutch pack relaxes.
    Fig 31: Pressing Down On Reverse Clutch And Zero Indicator

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34. 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.
35. 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:
    REVERSE CLUTCH SNAP RING THICKNESS SPECIFICATION
    
    

    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.)

36. To complete the assembly, reverse clutch and overdrive clutch must be removed.
37. Install the #2 needle bearing (Fig 32).
    Fig 32: Installing No. 2 Needle Bearing

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38. Install the underdrive shaft assembly (Fig 33).
    Fig 33: Installing Underdrive Shaft Assembly

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39. Install the #3 thrust washer to the underdrive shaft assembly. Be sure five tabs are seated properly (Fig 34).
    Fig 34: Installing No. 3 Thrust Washer

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40. Install the #3 thrust plate to the bottom of the overdrive shaft assembly. Retain with petrolatum or transmission assembly gel (Fig 35).
    Fig 35: Installing No. 3 Thrust Plate

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41. Install the overdrive shaft assembly (Fig 36).
    Fig 36: Installing Overdrive Shaft Assembly

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42. Reinstall overdrive and reverse clutch as shown. Rechecking these clutch clearances is not necessary.