Assembly

Use petrolatum on all seals to ease assembly of components.

Fig. 254:

1. Using an arbor press, install input shaft to input shaft hub (Fig. 254).

Fig. 255:

2. Install input shaft snap ring (Fig. 255).

Fig. 256:

Fig. 257:

3. Using an arbor press and Tool 6057, Install OD/Reverse piston return spring and snap ring (Fig. 256) (Fig. 257).

Fig. 258:

4. Install the OD/Reverse piston assembly to the input clutch retainer as shown in (Fig. 258).

NOTE: The OD/UD Reaction Plate, Snap Rings, and Input Clutches Retainer is not interchangeable with previous year 41TE components. The snap rings are thicker and the position of the ring lands have changed.

Fig. 259:

5. Install the input hub/shaft assy. to the OD/Reverse piston/clutch retainer assy. (Fig. 259).

Fig. 260:

6. Install input hub tapered snap ring (Fig. 260).

Fig. 261:

7. Install UD clutch piston (Fig. 261).

Fig. 262:

8. Install UD piston return spring and Tool 5067 as shown in (Fig. 262).

Fig. 263:

Fig. 264:

9. Using Tool 5059A and an arbor press, Install the UD spring retainer and snap ring. (Fig. 263) (Fig. 264) Compress just enough to install snap ring.

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

Fig. 265:

10. Install the UD clutch pack (four fibers/four steels) (Fig. 265).

Fig. 266:

11. Install the UD clutch flat snap ring (Fig. 266).

Fig. 267:

12. Install the last UD clutch disc (Fig. 267).

Fig. 268:

Fig. 269:

13. Install the clutch reaction plate and snap ring (Fig. 268) (Fig. 269). 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.

Fig. 270:

14. Seat tapered snap ring to ensure proper installation (Fig. 270).

Fig. 271:

15. Install input clutch assembly to the Input Clutch Pressure Fixture-Tool 8391 (Fig. 271).

Fig. 272:

16. Set up dial indicator on the UD clutch pack as shown in (Fig. 272).

Fig. 273:

17. Using moderate pressure, press down and hold (near indicator) the UD clutch pack with screwdriver or suitable tool and zero dial indicator (Fig. 273). 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).

Underdrive Reaction Plate Thickness Chart:

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

Fig. 274:

21. Install the OD clutch pack (four fibers/four steels) (Fig. 274).

Fig. 275:

22. Install OD reaction plate waved snap ring (Fig. 275).

Fig. 276:

23. Install the OD/Reverse reaction plate with large step down (towards OD clutch pack) (Fig. 276).

Fig. 277:

24. Install OD reaction plate flat snap ring (Fig. 277).
25. Measure OD clutch pack clearance. Set up dial indicator on top of the OD/Reverse reaction plate
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.

Fig. 278:

Fig. 279:

28. Install reverse clutch pack (two fibers/one steel) (Fig. 279).

Fig. 280:

29. Install reverse clutch reaction plate with the flat side down towards reverse clutch (Fig. 280).

Fig. 281:

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

Fig. 282:

31. Pry up reverse reaction plate to seat against snap ring (Fig. 282).

Fig. 283:

32. Set up a dial indicator on the reverse clutch pack as shown in (Fig. 283).

Fig. 284:

33. Using moderate pressure, press down and hold (near indicator) reverse clutch disc with screwdriver or suitable tool and zero dial indicator (Fig. 284). 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.

Reverse Clutch Snap Ring Thickness Chart:

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.