Overdrive/Direct Clutch (4,5,6) Disassembly and Assembly

1. Remove the Overdrive (O/D) (4, 5, 6) clutch hub.





2. Remove the O/D (4, 5, 6) clutch hub, No 2 thrust bearing See Figure 33.

3. Remove the O/D (4, 5, 6) clutch snap ring. See Figure 33.

4. Remove the O/D (4, 5, 6) clutch pressure plate and discard the clutch pack. See Figure 33.

5. Install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor # 30758911 and Forward/Intermediate Spring Compressor 30758412 on the balance piston.





6. Using a press compress the O/D (4, 5, 6) clutch return spring and remove the snap ring. See Figure 34.

7. Remove the Overdrive Clutch Balance Piston and Direct Clutch Compressor # 307-589/1 and Forward/Intermediate Spring Compressor # 307584/2.





8. Remove and discard the balance piston See Figure 35.





9. Remove the O/D (4, 5 6) piston return spring. See Figure 36.





10. Install the No.1 O/D/direct clutch assembly thrust bearing. See Figure 37.

11. Position the O/D/direct clutch assembly in the transaxle case.





12. Apply compressed air to the O/D (4 5, 6) clutch piston port and remove the O/D (4, 5, 6) clutch piston. See Figure 38.

13. Remove the O/D/direct clutch assembly from the transaxle case.





14. Remove and discard the O/D (4, 5, 6) clutch piston inner seal from the O/D/direct clutch assembly. See Figure 39.

15. Remove and discard the 2 seals from the O/D (4, 5, 6) clutch piston





16. Install 2 new seals on the O/D (4, 5, 6) clutch piston and lubricate the seals with petroleum jelly. See Figure 40.





17. Install a new O/D (4, 5, 6) clutch piston inner seal and lubricate the seal with petroleum jelly. See Figure 41.

18. Position the O/D (4, 5, 6) clutch piston in place.





19. Using the Overdrive Clutch, Balance Piston, and Direct Clutch Compressor # 30758911,install the O/D (4, 5, 6) clutch piston into the O/D/direct clutch assembly by hand. See Figure 42.

20. NOTE: Position the O/D (4, 5, 6) clutch piston return spring with the holes facing upward Install the O/D (4, 5, 6) clutch piston return spring.





21. Lubricate the seals on the new balance piston and position the balance piston in place. See Figure 43.

22. Install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor # 30758911 and Forward/Intermediate Spring Compressor # 30758412 on the balance piston.





23. Using a press compress the O/D (4, 5, 6) clutch return spring and install the snap ring. See Figure 44.

24. Remove the Overdrive Clutch, Balance Piston and Direct Clutch Compressor # 307589/1 and Forward/Intermediate Spring Compressor # 307-584/2





25. Install the No 2 thrust bearing. See Figure 45.





26. Install the O/D (4, 5, 6) clutch hub. See Figure 46.





27. Soak the new O/D (4, 5, 6) clutch pack in clean automatic transmission fluid. See Figure 47.

28. Install the new O/D (4. 5, 6) clutch pack.

29. Install the O/D (4, 5, 6) clutch pressure plate.

30. Install the O/D (4, 5, 6) clutch snap ring.





31. Position the O/D/direct clutch assembly in the transaxle case, install Dial Indicator Gauge with Holding Fixture # 100002 or a suitable dial indicator and position the plunger on the O/D (4, 5, 6) clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the O/D (4, 5, 6) clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.950 mm (0.037 in) and 1.778 mm (0.07 in). If the clearance is out of range, check the O/D (4, 5, 6) clutch pack for correct installation. See Figure 48.

32. Remove Dial Indicator Gauge with Holding Fixture # 100-002, O/D/direct clutch assembly and the No. 1 O/D/direct clutch assembly thrust bearing.