Assembly

40TE AUTOMATIC TRANSAXLE

INPUT CLUTCH ASSEMBLY

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

Fig.251 Install Input Shaft:

(1) Using an arbor press (2) (Fig. 251), install input shaft (1) to input shaft hub (3).

Fig.252 Install Input Shaft Snap Ring:

(2) Install input shaft snap ring (3) (Fig. 252).

Fig.253 Return Spring And Snap Ring:

(3) Place OD/Reverse piston (1) (Fig. 253) return spring (2) and snap ring (3) into position.

Fig.254 Install Snap Ring:

(4) Using an arbor press (1) (Fig. 254) and Disc 6057 (4), Install OD/Reverse piston (5) return spring (6) and snap ring (3).

Fig.255 Install OD/Reverse Piston:

(5) Install the OD/Reverse piston assembly (1) (Fig. 255) to the input clutch retainer (2).

Fig.256 Install Input Shaft Hub Assembly:

(6) Install the input hub/shaft assembly. (1) (Fig. 256) to the OD/Reverse piston/clutch retainer assembly (2).

Fig.257 Install Input Hub Tapered Snap Ring:

(7) Install input hub tapered snap ring (2) (Fig. 257).

Fig.258 Underdrive Clutch Piston:

(8) Install UD clutch piston (1) (Fig. 258).

Fig.259 Seal Compressor Installer 5067:

(9) Install UD piston return spring (1) (Fig. 259) and Installer 5067 (2).

Fig.260 Underdrive Clutch Piston, Spring:

Refer to the exploded view as necessary when performing the following steps (Fig. 260):

Fig.261 UD Return Spring And Retainer:

(10) Place the UD spring retainer (1) (Fig. 261) and snap ring (2) into position.

Fig.262 Install UD Spring Retainer And Snap Ring:

(11) Using Compressor 5059A (6) (Fig. 262) 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.

Fig.263 Install Underdrive Clutch Pack:

(12) Install the UD clutch pack (1,2) (Fig. 263). Leave out upper disc, until snap ring is installed.

Fig.264 UD Clutch Flat Snap Ring:

(13) Install the UD clutch flat snap ring (1) (Fig. 264) using a screwdriver (2).

Fig.265 Install Last UD Clutch Disc:

(14) Install the last UD clutch disc (1) (Fig. 265).

Fig.266 OD/UD Reaction Plate:

(15) Place the OD/UD clutch reaction plate (1) (Fig. 266) 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.

Fig.267 Tapered Snap Ring:

(16) Install the snap ring (1) (Fig. 267) 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.

Fig.268 Seating Tapered Snap Ring:

(17) Seat tapered snap ring (1) (Fig. 268) to ensure proper installation.

Fig.269 Input Clutch Assembly On Pressure Fixture Tool 8391:

(18) Install input clutch assembly (1) (Fig. 269) to the Input Clutch Pressure Fixture Tool 8391 (2).

Fig.270 Set Up Dial Indicator To Measure UD Clutch Clearance:

(19) Set up dial indicator (1) (Fig. 270) on the UD clutch pack (2).

Fig.271 Press Down On UD Clutch Pack And Zero Dial Indicator:

(20) Using moderate pressure, press down and hold (near indicator) (1) (Fig. 271) the UD clutch pack (2) with screwdriver or suitable tool and zero dial indicator. When releasing pressure on clutch pack, indicator reading should advance 0.005 - 0.010 inch.

CAUTION: Do not apply more than 30 psi (206 kPa) to the underdrive clutch pack.

(21) 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.
(22) Take average of four measurements and compare with UD clutch pack clearance specification. Underdrive clutch pack clearance must be 0.941.50 mm (0.037 - 0.059 inch).

Underdrive Reaction Plate Thickness:

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

Fig.272 Install Overdrive Clutch Pack:

(24) Install the OD clutch pack (1,2) (Fig. 272).

Fig.273 Install Waved Snap Ring:

(25) Install OD pressure plate waved snap ring (1) (Fig. 273) using a screwdriver (2).

Fig.274 OD/Reverse Reaction Plate:

(26) Install the OD/Reverse pressure plate (1) (Fig. 274) with large step down (towards OD clutch pack)(2).

Fig.275 Overdrive Clutch Assembly:

Refer to the exploded view (Fig. 275) as necessary when performing the following steps:

Fig.276 Install Flat Snap Ring:

(27) Install OD pressure plate flat snap ring (3) (Fig. 276) using Compressor 5059A (2) and an arbor press (1).

Fig.277 Measure OD Clutch Pack Clearance:

(28) Measure OD clutch pack clearance. Set up dial indicator (1) (Fig. 277) on top of the OD/Reverse pressure plate (2).
(29) Zero dial indicator and apply 30 psi (206 kPa) air pressure to the overdrive clutch hose on Input Clutch Pressure Fixture 8391. Measure and record OD clutch pack measurement in four (4) places, 90° apart.
(30) 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.

Fig.278 Install Reverse Clutch Pack:

(31) Install reverse clutch pack (two frictions /one steel) (1,2) (Fig. 278).

Fig. 279 Install Reaction Plate:

(32) Install reverse clutch reaction plate with the flat side down towards reverse clutch (1) (Fig. 279).

Fig.280 Reverse Clutch Assembly:

Refer to the exploded view (Fig. 280) as necessary when performing the following steps:

Fig.281 Install Reverse Clutch Snap Ring:

(33) Tap reaction plate (3) (Fig. 281) down to allow installation of the reverse clutch snap ring (1). Install reverse clutch snap ring (1).

Fig.282 Pry Up Reaction Plate:

(34) Pry up reverse reaction plate (1,3 and 4) (Fig. 282) to seat against snap ring (2).

Fig.283 Measure Reverse Clutch Pack Clearance:

(35) Set up a dial indicator (1) (Fig. 283) on the reverse clutch pack (2).

Fig.284 Press Down On Reverse Clutch And Zero Indicator:

(36) Using moderate pressure, press down and hold (near indicator) reverse clutch disc (2) (Fig. 284) with screwdriver or suitable tool and zero dial indicator (1). When releasing pressure, indicator should advance 0.005 - 0.010 inch as clutch pack relaxes.
(37) Apply 30 psi (206 kPa) air pressure to the reverse clutch hose on Input Clutch Pressure Fixture 8391. Measure and record reverse clutch pack measurement in four (4) places, 90° apart.

Reverse Clutch Snap Ring Thickness:

(38) 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:
(39) To complete the assembly, reverse clutch and overdrive clutch must be removed.

Fig.285 Install No.2 Needle Bearing:

(40) Install the #2 needle bearing (1) (Fig. 285) (tabs up) (2).

Fig.286 Install Underdrive Shaft Assembly:

(41) Install the underdrive shaft assembly (1) (Fig. 286).

Fig.287 Install No.3 Thrust Washer:

(42) Install the #3 thrust washer (1) (Fig. 287) to the underdrive shaft assembly (2). Be sure five tabs are seated properly.

Fig.288 Install No.3 Thrust Plate:

(43) Install the #3 thrust plate (note 3 tabs) (3) (Fig. 288) to the bottom of the overdrive shaft assembly (1). Retain with petrolatum or transmission assembly gel (2).

Fig.289 Underdrive Clutch Assembly:

Refer to the exploded view (Fig. 289) as necessary when performing the following steps:

Fig.290 Install Overdrive Shaft Assembly:

(44) Install the overdrive shaft assembly (Fig. 290).
(45) Reinstall overdrive and reverse clutch as shown. Rechecking these clutch clearances is not necessary.