Assembly

41TE AUTOMATIC TRANSAXLE

INPUT CLUTCH ASSEMBLY

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

Fig.248 Install Input Shaft:

(1) Using an arbor press (2), install input shaft (1) to input shaft hub (3) (Fig. 248).

Fig.249 Install Input Shaft Snap Ring:

(2) Install input shaft snap ring (3) (Fig. 249).

Fig.250 Return Spring And Snap Ring:

(3) Place OD/Reverse piston (1) (Fig. 250) return spring (2) and snap ring (3) into position.

Fig.251 Install Snap Ring:

(4) Using an arbor press (1) (Fig. 251) and Disk 6057 (4), install OD/Reverse piston (5) return spring (6) and snap ring (3).

Fig.252 Install OD/Reverse Piston:

(5) Install the OD/Reverse piston assembly (1) (Fig. 252) to the input clutch retainer (2).

Fig.253 Install Input Shaft Hub Assembly:

(6) Install the input hub/shaft assembly. (rotate to align splines) (1) (Fig. 253) to the OD/Reverse piston/clutch retainer assembly (2).

Fig.254 Input Clutch Hub, Retainer, And OD/Reverse Piston:

(7) Refer to the exploded view as necessary when performing the following steps (Fig. 254).

Fig.255 Install Input Hub Tapered Snap Ring:

(8) Install input hub tapered snap ring (tapered side up with tabs in cavity) (2) (Fig. 255).

Fig.256 Underdrive Clutch Piston:

(9) Install UD clutch piston (1) (Fig. 256).

Fig.257 Seal Compressor Special Tool 5067:

(10) Install UD piston return spring (1) (Fig. 257) and Installer 5067 (2).

Fig.258 Underdrive Clutch Piston, Spring And Retainer:

(11) Refer to the exploded view as necessary when performing the following steps.

Fig.259 UD Return Spring And Retainer:

(12) Place the UD spring retainer (1) (Fig. 259) and snap ring (2) into position.

Fig.260 Install UD Spring Retainer And Snap Ring:

(13) Using Compressor 5059A (6) (Fig. 260) 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.261 Underdrive Clutch Pack:

(14) Install the UD clutch pack (1,3) (Fig. 261). Leave out upper disc (2), until snap ring is installed.

Fig.262 UD Clutch Flat Snap Ring:

(15) Install the UD clutch flat snap ring (1) (Fig. 262).

Fig.263 Install Last UD Clutch Disc:

(16) Install the last UD clutch disc (1) (Fig. 263).

Fig.264 OD/UD Reaction Plate:

(17) Place the OD/UD clutch reaction plate (1) (Fig. 264) 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.265 Tapered Snap Ring:

(18) Install the snap ring (1) (Fig. 265) 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.266 Underdrive Clutch Assembly:

(19) Refer to the exploded view as necessary when performing the following steps (Fig. 266).

Fig.267 Seating Tapered Snap Ring:

(20) Seat tapered snap ring (1) (Fig. 267) to ensure proper installation.

Fig.268 Input Clutch Assembly On Pressure Fixture Tool 8391:

(21) Install input clutch assembly (1) to the Input Clutch Pressure Fixture 8391 (2) (Fig. 268).

Fig.269 Set Up Dial Indicator To Measure UD Clutch Clearance:

(22) Set up dial indicator (1) on the UD clutch pack (2) (Fig. 269).

Fig.270 Press Down On UD Clutch Pack And Zero Dial Indicator:

(23) Using moderate pressure, press down and hold (near indicator) the UD clutch pack (2) with screwdriver or suitable tool and zero dial indicator (Fig. 270). When releasing pressure on clutch pack, indicator reading should advance 0.005 - 0.010.

CAUTION: Do not apply more than30 psi (206 kPa) to the underdrive clutch pack.

(24) Apply 30 psi (206 kPa) to the underdrive hose on Input Clutch Pressure Fixture 8391 and measure UD clutch clearance. Measure and record UD clutch pack measurement in four (4) places, 90° apart.
(25) Take average of four measurements and compare with UD clutch pack (2) clearance specification. Underdrive clutch pack clearance must be 0.94 - 1.50 mm (0.037 - 0.059 inch).

Underdrive Reaction Plate Thickness:

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

Fig.271 Install OD Clutch Pack:

(27) Install the OD clutch pack (four frictions /three steels) (1) (Fig. 271).

Fig.272 Install Waved Snap Ring:

(28) Install OD pressure plate waved snap ring (1) (Fig. 272).

Fig.273 OD/Reverse Pressure Plate:

(29) Install the OD/Reverse pressure plate (1) with large step down (towards OD clutch pack) (2) (Fig. 273).

Fig.274 Overdrive Clutch Assembly:

(30) Refer to the exploded view as necessary when performing the following steps (Fig. 274).

Fig.275 Install Flat Snap Ring:

(31) Install OD pressure plate flat snap ring (3) (Fig. 275).

Fig.276 Measure OD Clutch Pack Clearance:

(32) Measure OD clutch pack clearance. Set up dial indicator (1) (Fig. 276) on top of the OD/Reverse pressure plate.
(33) 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.
(34) 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.277 Install Reverse Clutch Pack:

(35) Install reverse clutch pack (two frictions /one steel) (1,2) (Fig. 277).

Fig.278 Install Reaction Plate:

(36) Install reverse clutch reaction plate with the flat side down towards reverse clutch (Fig. 278).

Fig.279 Reverse Clutch Assembly:

(37) Refer to the exploded view as necessary when performing the following steps (Fig. 279).

Fig.280 Install Reverse Clutch Snap Ring:

(38) Tap reaction plate (3) (Fig. 280) down to allow installation of the reverse clutch snap ring (1) Install reverse clutch snap ring (1).

Fig.281 Pry Up Reaction Plate To Set Against Snap Ring:

(39) Pry up reverse reaction plate (4) (Fig. 281) to seat against snap ring (2).

Fig.282 Measure Reverse Clutch Pack Clearance:

(40) Set up a dial indicator (1) (Fig. 282) on the reverse clutch pack (2).

Fig.283 Press Down On Reverse Clutch And Zero Indicator:

(41) Using moderate pressure, press down and hold (near indicator) reverse clutch disc (2) (Fig. 283) with screwdriver or suitable tool and zero dial indicator (1). When releasing pressure, indicator should advance 0.005 - 0.010 as clutch pack relaxes.
(42) 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:

(43) 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:
(44) To complete the assembly, reverse clutch and overdrive clutch must be removed.

Fig.284 Install No.2 Needle Bearing:

(45) Install the #2 needle bearing (note 3 small tabs up) (1) (Fig. 284).

Fig.285 Install Underdrive Shaft Assembly:

(46) Install the underdrive shaft assembly (1) (Fig. 285).

Fig.286 Install No.3 Thrust Washer:

(47) Install the #3 thrust washer (1) (Fig. 286) to the underdrive shaft assembly (2). Be sure five tabs are seated properly.

Fig.287 Install No.3 Thrust Plate:

(48) Install the #3 thrust plate (3) (Fig. 287) (note 3 tabs) to the bottom of the overdrive shaft assembly (1). Retain with petrolatum or transmission assembly gel (2).

Fig.288 Overdrive/Underdrive Shafts:

(49) Refer to the exploded view as necessary when performing the following steps (Fig. 288).

Fig.289 Install Overdrive Shaft Assembly:

(50) Install the overdrive shaft assembly (1) (Fig. 289).
(51) Reinstall overdrive and reverse clutch as shown. Rechecking these clutch clearances is not necessary.