Direct Clutch Drum Assembly: Assembly

Inspect the clutch components for damage or wear. Install new components as necessary.
- Inspect the drum surface for damage.
- Inspect the clutch piston bore, and piston.
- Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
- Inspect the clutch plates for damage.
- Inspect the clutch springs.

CAUTION: The lip seals must be positioned as shown. Care must be taken to prevent rollover of the lip seal.

NOTE: Use new seals to help prevent seal failures.

Fig 1: Installing Direct Clutch Piston Inner & Outer Seals

Install the new direct clutch piston inner seal and the direct clutch piston outer seal.
Verify the check ball is free to move.

Fig 2: Identifying Check Ball

CAUTION: Care must be taken to prevent damage to the seals during installation.

Fig 3: Installing Direct Clutch Piston

Using the special tool, install the direct clutch piston.
Install the direct clutch piston springs and the retainer.

Fig 4: Identifying Direct Clutch Piston Springs & Retainer
Relieve the direct clutch spring tension and remove the special tool.

WARNING: After removing the retaining ring, use care when releasing the pressure on the springs. Failure to follow these instructions may result in personal injury.

CAUTION: Do not fully compress the special tool or damage to the spring retainer may occur.

Fig 5: Identifying Direct Clutch Piston Retaining Ring

Using the special tool, install the direct clutch piston retaining ring.

CAUTION: The direct clutch friction plates are directional and must be installed correctly. Alternate the internally splined (clockwise) and the externally splined (counterclockwise) clutch plates.

CAUTION: If new plates are used, they should be soaked in clean automatic transmission fluid for at least 30 minutes before assembly.

Fig 6: Identifying Internally Splined (Clockwise) & Externally Splined (Counterclockwise) Clutch Plates

When installing friction plates, alternate the internally splined (clockwise) and the externally splined (counterclockwise) clutch plates. Install the direct clutch disc pack.
Install the friction plates alternating the internally splined (clockwise) and the externally splined (counterclockwise) clutch plates starting with an externally splined (counterclockwise) clutch plate.

Fig 7: Identifying Clutch Plates

CAUTION: The retaining ring is a select fit.

Fig 8: Identifying Direct Clutch Pressure Plate

Install the direct clutch pressure plate using the original direct clutch retaining ring.

WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air, and make sure drum is facing down as shown. Failure to follow these instructions may result in personal injury.

Fig 9: Identifying Hole In Drum

Air check the assembly.
- Apply air pressure to the hole in the drum while blocking the other hole with a finger.
Push down on direct clutch disc pack and check gap between the direct clutch retaining ring and the direct clutch pressure plate with a feeler gauge.
- If specifications do not match use a select fit direct clutch retaining ring to match specifications and verify with a feeler gauge.
Fig 10: Checking Gap Between Direct Clutch Retaining Ring & Direct Clutch Pressure Plate

Fig 11: Identifying Select Fit Direct Clutch Retaining Ring Thicknesses