Disassembly

FIGURE 7:

1. Remove the overdrive clutch wire retaining ring, then pull out the alternating metal and friction clutch components. Note that the heaviest metal plate is placed in the front of the clutch pack. This is the pressure plate (Figure 7).

FIGURE 8:

2. Take a close look at each clutch component for signs of wear. Replace if necessary (Figure 8).

FIGURE 9:

3. Next, take out the wave ring. This special ring acts as a cushion to absorb the shock when the overdrive clutch engages (Figure 9).

FIGURE 10:

In the same groove, there is another large flat snap ring to be removed (Figure 10).

FIGURE 11:

4. Unscrew the two Phillips screws and remove the access plate from the top of the case (Figure 11). The snap ring holds the output shaft front bearing in place.

FIGURE 12:

FIGURE 13:

5. Because the entire case must be inverted to remove the gear train, insert the alignment tool (Miller special tool C-6227-2) into the sun gear. After seating it (Figure 12), invert the case on the alignment tool (Figure 13). Use expanding snap ring pliers to expand the output shaft front bearing snap ring and carefully lift the case off the gear train.

FIGURE 14:

6. Remove governor retaining snap ring. Remove the governor and shaft key (Figure 14). This will prevent damaging the governor when the direct clutch spring is compressed in the arbor press. Set the gear train aside and continue disassembly of the case components.

FIGURE 15:

FIGURE 16:

7. Remove the output shaft front bearing snap ring (Figure 15), then remove the governor support snap ring. Take the governor support with slip-fit tubes out of the case (Figure 16).

FIGURE 17:

8. Using locking snap ring pliers, remove the output shaft rear bearing snap ring (Figure 17).
Now, by tapping the case downward on the bench, the bearing should drop out.

FIGURE 18:

9. To remove the parking mechanism, first remove the reaction plug snap ring (Figure 18). Care should be taken to compress the snap ring only enough to allow its removal.

FIGURE 19:

FIGURE 20:

Next, unscrew the bolt securing the dowel and parking pawl (Figure 19). Now, another light tap to the case on the bench will cause the dowel, the parking pawl, and the reaction plug to drop out on the bench (Figure 20).
10. At the rear of the case, a standard A-727 rear transmission bushing and seal are used at the output shaft. Now that the case is disassembled you may continue disassembly of the gear train.

11. It is very important that you use a press capable of three inches of travel to compress the direct clutch spring. A press must have the three-inch travel required to perform this critical step safely. The spring exerts over 800 pounds of force on the sliding hub. Spring tension must be released slowly and completely to avoid personal injury.

FIGURE 21:

12. Place the output shaft in a fixture that will support the output shaft flange. With the assembly properly supported in the press, place the special tool, C-6227-1, in place (Figure 21). Have a helper operate the press to compress the direct clutch spring.

FIGURE 22:

FIGURE 23:

13. When the hub is compressed, you will now be able to safely remove the large load-retaining ring (Figure 22), and the small load-retaining safety ring (Figure 23). When your helper unloads the press, the direct clutch spring tension is relieved. The rest of the unit can be disassembled.

FIGURE 24:

14. Remove the sliding hub with the direct clutch on it. Remove the components of the clutch from the hub and inspect them one at a time (Figure 24).

FIGURE 25:

15. Next, remove the direct clutch spring, the sun gear, a needle bearing pack and the planet carrier (Figure 25).

FIGURE 26:

16. Next, to remove the overrunning clutch, invert the assembly and, with expanding snap ring pliers, reach into the inner splines of the clutch. You can remove the overrunning clutch intact with a quick counterclockwise twist (Figure 26). Also remove the needle bearing.

FIGURE 27:

17. Mark the direct clutch drum and the annulus for exact reassembly (Figure 27).

FIGURE 28:

FIGURE 29:

18. Two wire retaining rings secure the direct clutch drum to the annulus. Remove the inner one first (Figure 28), then the one behind the rear of the drum (Figure 29). Now slide the drum from the annulus.

FIGURE 30:

19. Mark the annulus and the output shaft for exact reassembly (Figure 30).

FIGURE 31:

20. To remove the annulus (one snap ring secures it to the output shaft) a light tap with a soft mallet will pop it off the shaft (Figure 31). Now the only component left is the output shaft front bearing which is a slip fit on the shaft.