Assembly

Use petrolatum on all seals to ease assembly of component.
1. Install input shaft to hub.




2. Install input shaft snap ring. Replace lip seals and D-rings. Do not scratch bearing surface.




3. Install return spring and snap ring. Replace O-ring and lip seal of OD/reverse piston.




4. While compressing return spring with Disc 6057 and arbor press ram, install snap ring with a screwdriver.




5. Install overdrive/reverse piston by pushing down. Be sure to lubricate reverse piston O-ring and lip seal prior to installation.




6. To install input shaft hub assembly to overdrive/reverse piston, rotate input shaft hub to align splines with overdrive/reverse piston and push down by hand.




7. Install input hub tapered snap ring with snap ring pliers.




8. Install underdrive clutch piston.




9. Install piston return spring. Install Seal Installer 5067. Coat Installer inner surface lightly with petroleum jelly. Place Installer into Input clutch assembly with its large inside diameter facing up.




10. Install underdrive spring retainer. Remove Installer 5067.




11. While compressing spring with Spring Compressor 5059 and arbor press ram, install snap ring with snap ring pliers.

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




12. Install underdrive clutch pack excluding one clutch disc.




13. Install underdrive clutch reaction plate flat snap ring with a screwdriver.




14. Install last underdrive clutch disc.




15. Install overdrive/underdrive clutch reaction plate with stepped side facing down.




16. Install a new overdrive/underdrive clutches reaction plate tapered snap ring with its tapered side facing up.

CAUTION: Do not reuse tapered snap ring.




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.

CAUTION: Do not scratch reaction plate.




17. Set up dial indicator and steel bar as shown for checking clutch clearance. Compress clutch pack with finger to zero dial indicator.




18. Use hook tool to raise top clutch disc. Read dial indicator. Underdrive clutch pack clearance must be 0.91 to 1.47 mm (0.0358 to 0.0579 inch). Select the proper reaction plate to achieve specifications:




19. Install overdrive clutch pack starting with a clutch disc.




20. Install overdrive reaction plate waved snap ring into the wide groove.







21. Install overdrive/reverse pressure plate with stepped side down.




22. While pressure down overdrive/reverse pressure plate with Spring Compressor 5059 and arbor press ram, install flat snap ring.

CAUTION: Press down just enough to expose snap ring groove.




23. Check overdrive clutch pack clearance.
The overdrive (OD) clutch pack clearance is 1.07 to 2.44 mm (0.421 to 0.0961 inch). If not within specifications, the clutch is not assembled properly. There is no adjustment for the OD clutch clearance.




24. Install reverse clutch pack.




25. Install reverse clutch reaction plate with flat side down.




26. Install reverse clutch snap ring with a screwdriver.




27. Raise reverse clutch reaction plate by prying up at two locations with screwdrivers to seat snap ring.




28. Check reverse clutch pack clearance by lifting reverse clutch reaction plate using a hook tool.

The reverse clutch pack clearance is 0.76 to 1.24 mm (0.0299 to 0.0488 inch). Select the proper reverse clutch snap ring to achieve specifications.




All clutch clearances in the input clutch retainer have now been checked and approved. To complete the assembly of the input clutch retainer, the reverse clutch and the overdrive clutch must be removed from the retainer.

CAUTION: Do not intermix clutch parts. Keep In the same order.

29. After removing reverse and overdrive clutches, install No. 2 needle bearing with 3 small tabs facing up.




30. Install underdrive shaft assembly.




31. Install No.3 thrust washer.




32. Stick No.3 thrust plate onto overdrive shaft assembly with dabs of petrolatum.




33. Install overdrive shaft assembly.
Now that both shaft assemblies and thrust washers are properly installed, reinstall overdrive clutch and reverse clutch as shown in step 19-26.
Rechecking these clutch clearances is not necessary, as they were set and approved previously.




34. Reassembly of input clutch assembly is now complete.