Assembly
FIGURE 32:
1. Before assembling, clean all the parts and dry them with compressed air. Never clean or dry parts with shop towels as lint deposits could plug oil filter.
To assemble the overdrive unit, align the mating marks, then insert the shaft through the back of the annulus and secure it with the snap ring (Figure 32).
FIGURE 33:
2. Next, set the direct clutch drum face down and align the other set of mating marks. Insert the annulus lugs into the slots inside the drum. Install the rear wire retaining ring first. Then invert the assembly. Slide the drum forward to expose the retaining ring groove. Then install the front wire retaining ring to secure the drum (Figure 33).
3. Hold the overrunning clutch upside down with expanding snap ring pliers. Place the needle bearing against the back face of the clutch. Now, hold the shaft assembly upside down, and with an upward counterclockwise twisting motion, install the overrunning clutch.
FIGURE 34:
FIGURE 35:
4. Carefully set the carrier assembly into the annulus (Figure 34) and align the splines using special tool C-6227-2 (Figure 35).
FIGURE 36:
5. Set the needle bearing in place, remove the tool, and install the sun gear (Figure 36). Set the spring on the sun gear, then place the sliding hub on the spring. Reinstall the alignment tool and install the direct clutch plates one at a time on the hub.
FIGURE 37:
FIGURE 38:
FIGURE 39:
6. This step involves compressing the direct clutch spring with the arbor press. Set special tool, C-6227-1, on the hub and compress the spring. Remember, you'll need a helper to operate the press because, as the spring is compressed, you must slide the clutch plates into their grooves and down the hub (Figure 37.) Then install the large load-retaining snap ring, seating it firmly with a large screwdriver (Figure 38). Now install the safety ring (Figure 39). Slowly release the press, ensuring that the loadretaining rings are properly seated. Install governor and snap ring.
FIGURE 40:
7. Set the gear train aside, with special alignment tool still in place, then reassemble the parking mechanism into the case.
8. Install the dowel, parking pawl and spring back into the case (Figure 40). Then reinstall the retaining bolt and torque it to 20 foot-pounds (27 N-m). Next, position the reaction plug in place and secure it with its snap ring. Use care to squeeze the snap ring only enough to install it.
FIGURE 41:
9. Set the output shaft rear bearing in the case, ensuring that the groove is toward the front of the case (Figure 41).
FIGURE 42:
FIGURE 43:
10. Then install the governor support (Figure 42) and secure it with its snap ring into the overdrive housing (Figure 43).
FIGURE 44:
11. Install the output shaft front bearing snap ring in the case. Make sure the alignment tool is reinstalled in the gear train. Invert the gear train and slip the case over the shaft.
12. Expand the snap ring and slip the case down until the ring locks in the bearing groove. Release the snap ring.
13. After reinstalling the access plate and gasket, install the flat snap ring. Use a large screwdriver to be sure that it's seated properly. Then reinstall the wave ring (Figure 44) using the same seating technique.
FIGURE 45:
14. One by one, install the overdrive clutch plates, be certain to put the thickest plate in last (Figure 45).
FIGURE 46:
15. Position the overdrive unit vertically in a large vise. To determine the proper intermediate shaft spacer thickness, insert special tool (C-6312) through the sun gear. Be sure that the tool bottoms against the carrier spline shoulder. Position special tool (C-6311) across overdrive case face. Using dial caliper tool (C-4962), positioned over tool C-6311, measure distance to the top of tool C-6312 (Figure 46).
Using this measurement, select the proper thickness spacer from the chart.
Intermediate Shaft Spacer Chart
Measurement Use Spacer Thickness
(Inches) Spacer No. (Inches)
.7336-.7505 4431916 .159-.158
.7506-.7675 4431917 .176-.175
.7676-.7855 4431918 .194-.193
.7856-.8011 4431919 .212-.211
FIGURE 47:
16. To determine the proper shim thickness for the overdrive piston: Position special tool, C-6311, across overdrive case face. Then using dial caliper tool (C-4962) positioned over tool C-6311, measure distance to the sliding hub bearing seat (Figure 47).
This measurement should be taken at four locations 90~ apart. Add all measurements together and divide by four (4). Using this measurement, select the proper thickness shim from the chart.
Overdrive Piston Shim Chart
Measurement Use Shim Thickness
(Inches) Shim No. (Inches)
1.7500-1.7649 4431730 .108-.110
1.7650-1.7799 4431585 .123-.125
1.7800-1.7949 4431731 .138-.140
1.7950-1.8099 4431586 .153-.155
1.8100-1.8249 4431732 .168-.170
1.8250-1.8399 4431587 .183-.185
1.8400-1.8549 4431733 .198-.200
1.8550-1.8699 4431588 .213-.215
1.8700-1.8849 4431734 .228-.230
1.8850-1.8999 4431590 .243-.245