Assembly - Input Clutch: Disassembly

Fig 1: Tapping Reaction Plate

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1 - #4 THRUST PLATE (SELECT)

2 - TAP DOWN REVERSE CLUTCH REACTION PLATE TO REMOVE OR INSTALL SNAP RING

3 - INPUT CLUTCH RETAINER

4 - REVERSE CLUTCH REACTION PLATE

1. Mount input clutch assembly to Input Clutch Pressure Fixture (Tool 8391).
2. Tap down (2) reverse clutch reaction plate (4) to release pressure from snap ring. See Fig 1.
   Fig 2: Reverse Clutch Snap Ring

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   1 - REACTION PLATE

   2 - SCREWDRIVER

   3 - REVERSE CLUTCH SNAP RING (SELECT)

3. Remove reverse clutch snap ring (3). See Fig 2.
   Fig 3: Pry Reverse Clutch Reaction Plate

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   1 - REVERSE CLUTCH REACTION PLATE

   2 - SCREWDRIVER

   3 - SCREWDRIVER

4. Pry up reverse clutch reaction plate (1). See Fig 3.
   Fig 4: Reverse Clutch Reaction Plate

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   1 - REVERSE CLUTCH REACTION PLATE (INSTALL FLAT SIDE DOWN)

5. Remove reverse clutch reaction plate (1). See Fig 4.
   Fig 5: Reverse Clutch Pack

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   1 - REVERSE CLUTCH PLATE

   2 - REVERSE CLUTCH DISC

   NOTE: Tag reverse clutch pack for reassembly identification.
6. Remove the reverse clutch pack (two fibers/one steel) (1, 2). See Fig 5.
   Fig 6: OD/Reverse Pressure Plate Snap Ring

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   1 - OD/REVERSE PRESSURE PLATE

   2 - SCREWDRIVER

   3 - OD/REVERSE PRESSURE PLATE SNAP RING

7. Remove the OD/Reverse reaction plate (1) snap ring (3). See Fig 6.
   Fig 7: OD/Reverse Reaction Plate

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   1 - OD/REVERSE PRESSURE PLATE (STEP SIDE DOWN)

   2 - (STEP SIDE DOWN)

8. Remove OD/Reverse pressure plate (1). See Fig 7.
   Fig 8: Waved Snap Ring

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   1 - OVERDRIVE SHAFT ASSEMBLY

   2 - OD/REVERSE CLUTCH WAVED SNAP RING

   3 - SCREWDRIVER

9. Remove OD/Reverse reaction plate wave snap ring (2). See Fig 8.
   Fig 9: Remove OD Clutch Pack

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   1 - OVERDRIVE SHAFT ASSEMBLY AND OD CLUTCH PACK

   2 - #3 THRUST PLATE

   3 - #3 THRUST WASHER

   4 - UNDERDRIVE SHAFT ASSEMBLY

10. Remove OD shaft/hub and OD clutch pack (1). See Fig 9.
    Fig 10: Overdrive Clutch Pack

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    1 - OVERDRIVE CLUTCH PLATE

    2 - OVERDRIVE SHAFT ASSEMBLY

    3 - OVERDRIVE CLUTCH DISC

    NOTE: Tag overdrive clutch pack for reassembly identification.
11. Remove the overdrive clutch (1, 3) from the overdrive hub/shaft (2). See Fig 10.
    Fig 11: #3 and #4 Thrust Washers

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    1 - #3 THRUST PLATE (3 TABS)

    2 - OD SHAFT ASSEMBLY

    3 - #4 THRUST PLATE (3 SLOTS)

12. Remove and inspect number 3 and 4 thrust plates (1, 3). See Fig 11.
    Fig 12: Underdrive Shaft Assembly

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    1 - #3 THRUST WASHER (5 TABS)

    2 - UNDERDRIVE SHAFT ASSEMBLY

13. Remove the underdrive shaft assembly (2). See Fig 12.
    Fig 13: No 2 Needle Bearing

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    1 - #2 NEEDLE BEARING (NOTE 3 TABS)

14. Remove the number 2 needle bearing (1). See Fig 13.
    Fig 14: Tapered Snap Ring

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    1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING

    2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)

15. Remove the OD/UD reaction plate tapered snap ring (1). See Fig 14.
    Fig 15: OD/UD Reaction Plate

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

    NOTE: The OD/UD clutch reaction plate has a step on both sides. The OD/UD clutches reaction plate goes tapered step side up.
16. Remove the OD/UD reaction plate (1). See Fig 15.
    Fig 16: Remove Last UD Clutch Disc

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    1 - ONE UNDERDRIVE CLUTCH DISC

17. Remove the first UD clutch disc (1). See Fig 16.
    Fig 17: UD Clutch Flat Snap Ring

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    1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING

    2 - SCREWDRIVER

18. Remove the UD clutch flat snap ring (1). See Fig 17.
    Fig 18: Underdrive Clutch Pack

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    1 - CLUTCH PLATE

    2 - ONE UD CLUTCH DISC

    3 - CLUTCH DISC

    NOTE: Tag underdrive clutch pack for reassembly identification.
19. Remove the UD clutch pack (1, 3). See Fig 18.
    Fig 19: UD Spring Retainer Snap Ring

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    1 - SNAP RING PLIERS

    2 - ARBOR PRESS RAM

    3 - SNAP RING

    4 - SPECIAL TOOL 5059A

    CAUTION: Compress return spring just enough to remove or install snap ring.
20. Using Tool 5059A (4) and an arbor press (2), compress UD clutch piston enough to remove snap ring (3). See Fig 19.
    Fig 20: UD Return Spring and Retainer

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    1 - UNDERDRIVE SPRING RETAINER

    2 - SNAP RING

    3 - SEAL

    4 - PISTON RETURN SPRING

21. Remove the underdrive spring retainer snap ring (2), spring retainer (1), and spring (4). See Fig 20.
    Fig 21: Underdrive Clutch Piston

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    1 - PISTON

22. Remove the UD clutch piston (1). See Fig 21.
    Fig 22: 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

23. Remove the input hub tapered snap ring (2). See Fig 22.
    Fig 23: Tap on Input Hub

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    1 - INPUT SHAFT AND HUB ASSEMBLY

    2 - PLASTIC HAMMER

24. Tap on input hub (1) with soft faced hammer (2) and separate input hub from OD/Reverse piston and clutch retainer. See Fig 23.
    Fig 24: Input Hub Removed

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    1 - INPUT SHAFT AND HUB ASSEMBLY

    2 - INPUT CLUTCH RETAINER

    3 - O-RING

    4 - SEAL

    5 - OVERDRIVE/REVERSE PISTON

25. Separate the input hub from OD/Reverse piston (5) and clutch retainer (2). See Fig 24.
    Fig 25: Pull Retainer from Piston

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    1 - OVERDRIVE/REVERSE PISTON

    2 - INPUT CLUTCH RETAINER

26. Separate clutch retainer (2) from OD/Reverse piston (1). See Fig 25.
    Fig 26: Remove 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

27. Using Tool 6057 (4) and an arbor press (1), compress OD/Reverse piston (5) return spring just enough to remove snap ring (3). See Fig 26.
    Fig 27: Return Spring and Snap Ring

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    1 - OD/REVERSE PISTON

    2 - RETURN SPRING

    3 - SNAP RING

    4 - O-RING

28. Remove the OD/Reverse piston (5) return spring and snap ring (3). See Fig 27.
    Fig 28: Remove Input Shaft Snap Ring

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    1 - INPUT SHAFT

    2 - SHARP-POINTED TOOL

    3 - SNAP RING

    4 - O-RINGS

    5 - SEALS

29. Remove input shaft (1) to input clutch hub snap ring (3). See Fig 28.
    Fig 29: Remove Input Shaft

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    1 - ARBOR PRESS RAM

    2 - SOCKET

    3 - SEAL

    4 - O-RINGS

    5 - INPUT SHAFT

    6 - SEAL

    7 - INPUT CLUTCH HUB

30. Using a suitably sized socket (2) and an arbor press (1), remove input shaft (5) from input shaft hub. See Fig 29.