Overhaul

DISASSEMBLY/INSPECTION/ASSEMBLY
1. Disassemble in the order shown, Refering to the Disassembly Notes.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in reverse order of disassembly, Refering to the Assembly Notes.

DISASSEMBLY NOTES

Snap Ring (Coasting Clutch)

1. Install the SST in the coasting clutch drum as shown.
2. Compress the spring and retainer assembly.
3. Remove the snap ring.
4. Remove the SST, then remove the spring and retainer assembly.

Coasting Clutch Drum

1. Remove the coasting clutch drum from the reverse/forward drum by applying compressed air through the fluid passage.

Coasting Piston

1. Remove the coasting clutch piston from the coasting clutch drum by applying compressed air through the fluid passage.

Snap Ring (Reverse Clutch)

1. Install the SST in the reverse/forward drum as shown.
2. Compress the piston return spring.

3. Remove the snap ring from the groove with snap ring pliers.
4. Remove the SST (or equivalent) from the reverse/forward drum.

5. Remove the snap ring with a screwdriver.

Reverse Piston
1. Place the reverse/forward drum on the oil pump.

2. Remove the reverse piston by applying compressed air through the reverse clutch fluid passage.

INSPECTION

Drive Plates

1. Measure the facing thickness in three places and determine the average of the three readings.

Standard: 0.063 inch (1.6 mm)
Minimum: 0.055 inch (1.4 mm)

2. If not within specification, replace the drive plates.

Spring And Retainer Assembly

1. Measure the spring free length and check for deformation.

Free length: 0.805 inch (20.45 mm)

2. If not within specification, replace the spring and retainer assembly.

Reverse Clutch Piston

1. Verify that there is no air leakage when applying compressed air through the oil hole opposite the return spring.
2. Verify that there is air flow when applying compressed air through the oil hole on the return spring side.

Air pressure: 57 psi (392 kPa) maximum

Coasting Clutch Piston

1. Verify that there is air flow when applying compressed air through the backside of the drum.
2. Verify that there is no air leakage when applying compressed air through the inside of the drum.

ASSEMBLY NOTES

Reverse Clutch

1. Install the reverse clutch piston.
A. Apply ATF to inner and outer faces of the seals, and install them to the reverse clutch piston.
B. Insert the reverse clutch piston onto SST K94 4212-AT and install the SST and reverse clutch piston assembly onto the reverse/forward clutch drum.

C. Using SST K94 4212-AT, install the reverse piston by pushing evenly around the circumference, being careful not to damage the seal rings.
D. Hold the reverse clutch piston in position and remove the SST.

2. Install the piston return spring with the tabs facing away from the reverse clutch piston.
3. Install the return spring stop with the step facing upward.

4. Install the snap ring half-way down the reverse/forward drum as shown.

5. Install the SST on the reverse/forward drum.
6. Compress the spring and retainer assembly.
7. Install the snap ring with a screwdriver.
8. Remove the SST.

9. Install the dished plate with the dished side facing downward into the drum as shown.
10. Install the drive and driven plates.
11. Install the retaining plate.
12. Install the snap ring.

13. Measure the reverse clutch clearance.
A. Measure the clearance between the snap ring and the retaining plate of the reverse clutch.
B. If the clearance is not within specification, adjust it by selecting the correct thickness snap ring.

Reverse clutch clearance: 0.039 - 0.051 inch (1.0 - 1.3 mm)

Reverse clutch snap ring sizes:
0.079 (2.0)
0.102 (2.6)
0.087 (2.2)
0.110 (2.8)
0.095 (2 4)
0.118 (3.0)

Coasting Clutch

1. Install the coasting clutch drum.
A. Apply ATF to inner and outer faces of the seal, and install it onto the coasting clutch drum.
B. Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the drum.

C. Install the coasting clutch drum in the correct position in the reverse/forward drum as shown.
D. Push evenly around the circumference, being careful not to damage the outer seal.

2. Install the coasting clutch piston.
A. Apply ATF to inner and outer faces of the seals and install them onto the coasting clutch piston.
B. Insert the coasting clutch piston into SST K94A-4213-AT. and install the SST and coasting clutch piston assembly into the coasting clutch drum.

C. Using SST K94A-4213-AT, install the coasting clutch piston by pushing evenly around the circumference, being careful not to damage the outer seal.
D. Hold the coasting clutch piston in position and remove the SST.

3. Install the spring and retainer assembly.

4. Install the SST in the coasting clutch as shown.
5. Compress the spring and retainer assembly.
6. Install the snap ring.
7. Remove the SST.

8. Install the dished plate with the dished side facing out of the drum as shown.
9. Install the drive and driven plate.

NOTICE: Installation order - Driven-Drive-Driven-Drive

10. Install the retaining plate.
11. Install the snap ring.

12. Measure the coasting clutch clearance.
A. Measure the clearance between the snap ring and the retaining plate of the coasting clutch.
B. If the clearance is not within specification, adjust it by selecting the correct thickness snap ring.

Coasting clutch clearance: 0.039 - 0.048 inch (1.0 - 1.2 mm)

Coasting Clutch Snap Ring Sizes:
0.071 (1.8)
0.089 (2.25)
0.106 (2.7)
0.077 (1.95)
0.094 (2.4)
0.11.2 (2.85)
0.083 (2.1)
0.100 (2.55)

Forward Clutch

1. Install the dished plate with the dished side facing downward into the drum, as shown.
2. Install the drive and driven plates.

3. Install the retaining plate.
4. Install the snap ring.

5. Measure the forward clutch clearance.
A. Measure the clearance between the snap ring and the retaining plate of the forward clutch.
B. If the clearance is not within specification, adjust it by selecting the correct thickness snap ring.

Forward clutch clearance: 0.039 - 0.048 inch (1.0 - 1.2 mm)

Forward Clutch Snap Ring Sizes:
0.063 (1.6)
0.087 (2.2)
0.098 (2.5)
0.069 (1.75)
0.080 (2.05)
0.104 (2.65)
0 075 (1.9)
0.093 (2.35)

6. Check the clutch operation as follows:
A. Set the clutch assembly onto the oil pump.
B. Check the clutch operation by applying compressed air though the fluid passages shown.

7. Apply petroleum jelly to the thrust bearings, and secure them on each side of the reverse/forward drum.

Thrust bearing outer diameter:
Oil pump side: 3.39 inch (86.0 mm)

Small sun gear and one-way clutch side: 2.21 inch (56.1 mm)