Input Clutch Assembly

40TE TRANSAXLE

INPUT CLUTCH ASSEMBLY

DISASSEMBLY
1. Mount input clutch assembly to Input Clutch Pressure Fixture (Tool 8391).





2. Tap down reverse clutch reaction plate to release pressure from snap ring (Fig. 216).





3. Remove reverse clutch snap ring (Fig. 217).





4. Pry up and remove reverse clutch reaction plate (Fig. 218).





5. Remove reverse clutch pack (Fig. 219). Tag components for assembly identification.





6. Remove the OD/Reverse pressure plate snap ring (Fig. 220).
7. Remove OD/Reverse pressure plate (Fig. 220).
8. Remove OD/Reverse pressure plate wave snap ring (Fig. 220).
9. Remove OD clutch pack (Fig. 220). Tag components for assembly identification.





10. Remove and inspect OD and UD Shafts, as well as #3 thrust washer and plate, and #2 needle bearing (Fig. 221).





11. Remove the OD/UD reaction plate tapered snap ring, reaction plate, and first friction disc (Fig. 222).
12. Remove the UD clutch flat snap ring and rest of UD clutch pack (Fig. 222). Tag clutch pack for assembly identification.

CAUTION: Compress return spring just enough to remove or install snap ring.








13. Using Tool 5059A and an arbor press, compress UD clutch piston/spring enough to remove snap ring (Fig. 223) (Fig. 224).
14. Remove spring retainer, spring, and piston (Fig. 224).








15. Remove input hub tapered snap ring (Fig. 225) (Fig. 231).





16. Tap on input hub with soft faced hammer and separate input hub from OD/Reverse piston and clutch retainer (Fig. 226).





17. Separate clutch retainer from OD/Reverse piston (Fig. 227).





18. Using Tool 6057 and an arbor press, compress return OD/Reverse piston return spring just enough to remove snap ring (Fig. 228).





19. Remove input shaft to input clutch hub snap ring (Fig. 229) (Fig. 231).





20. Using a suitably sized socket and an arbor press, remove input shaft from input shaft hub (Fig. 230).

ASSEMBLY
Use petrolatum on all seals to ease assembly of components.





1. Using an arbor press, install input shaft to input shaft hub (Fig. 232).





2. Install input shaft snap ring (Fig. 233).








3. Using an arbor press and Tool 6057, Install OD/Reverse piston return spring and snap ring (Fig. 234) (Fig. 235).





4. Install the OD/Reverse piston assembly to the input clutch retainer as shown in (Fig. 236).





5. Install the input hub/shaft assy. to the OD/Reverse piston/clutch retainer assy. (Fig. 237).








6. Install input hub tapered snap ring (Fig. 238) (Fig. 239).





7. Install UD clutch piston (Fig. 240).





8. Install UD piston return spring and Tool 5067 as shown in (Fig. 241).











9. Using Tool 5059A and an arbor press, Install the UD spring retainer and snap ring (Fig. 242) (Fig. 243) (Fig. 244) Compress just enough to install snap ring.

CAUTION: Compress return spring just enough to install snap ring.





10. Install the UD clutch pack. Leave out upper disc, until snap ring is installed (Fig. 245).





11. Install the UD clutch flat snap ring (Fig. 246).





12. Install the last UD clutch disc (Fig. 247).








13. Install the OD/UD clutch reaction plate and snap ring (Fig. 248) (Fig. 249). The OD/UD clutches reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up.

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.








14. Seat tapered snap ring to ensure proper installation (Fig. 250) (Fig. 251).





15. Install input clutch assembly to the Input Clutch Pressure Fixture-Tool 8391 (Fig. 252).





16. Set up dial indicator on the UD clutch pack as shown in (Fig. 253).





17. Using moderate pressure, press down and hold (near indicator) the UD clutch pack with screwdriver or suitable tool and zero dial indicator (Fig. 254). 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.

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 inch).





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





21. Install the OD clutch pack (Fig. 255).





22. Install OD pressure plate waved snap ring (Fig. 256).





23. Install the OD/Reverse pressure plate with large step down (towards OD clutch pack) (Fig. 257).








24. Install OD pressure plate flat snap ring (Fig. 258) (Fig. 259).





25. Measure OD clutch pack clearance. Set up dial indicator on top of the OD/Reverse pressure plate as shown in (Fig. 260).
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 inch).
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. 261).





29. Install reverse clutch reaction plate with the flat side down towards reverse clutch (Fig. 262).








30. Tap reaction plate down to allow installation of the reverse clutch snap ring. Install reverse clutch snap ring (Fig. 263) (Fig. 264).





31. Pry up reverse reaction plate to seat against snap ring (Fig. 265).





32. Set up a dial indicator on the reverse clutch pack as shown in (Fig. 266).





33. Using moderate pressure, press down and hold (near indicator) reverse clutch disc with screwdriver or suitable tool and zero dial indicator (Fig. 267). When releasing pressure, indicator should advance 0.005-0.010. as clutch pack relaxes.
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 inch). Select the proper reverse clutch snap ring to achieve specifications:
36. To complete the assembly, reverse clutch and overdrive clutch must be removed.





37. Install the #2 needle bearing (Fig. 268).





38. Install the underdrive shaft assembly (Fig. 269).





39. Install the #3 thrust washer to the underdrive shaft assembly. Be sure five tabs are seated properly (Fig. 270).





40. Install the #3 thrust plate to the bottom of the overdrive shaft assembly Retain with petrolatum or transmission assembly gel (Fig. 271).








41. Install the overdrive shaft assembly (Fig. 272) (Fig. 273).
42. Reinstall overdrive and reverse clutch as shown. Rechecking these clutch clearances is not necessary.