Output Shaft and Direct Clutch Cylinder

Special Tools:

Disassembly

NOTE: The yellow dot on the output shaft must be aligned with the yellow dot on the output shaft ring gear during the assembly procedure.





1. Remove the ring gear snap ring.





2. Separate the (A) ring gear and (B) output shaft.





3. Remove the three output shaft seal rings.





4. Remove the (A) output shaft hub snap ring and the (B) output shaft hub.





5. Remove the two direct clutch seal rings.





6. Remove the (A) direct clutch hub and the (B) bearing and direct clutch inner bearing support.
7. Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or buffs. Minor scores or buffs may be removed with a crocus cloth. Replace the clutch cylinder if badly scored or damaged.
8. Check the fluid passage in the clutch cylinder for obstructions. Clean out all fluid passages. Inspect the clutch piston for scores and replace if necessary. Inspect the check balls for freedom of movement and proper seating.
9. Check clutch release spring for distortion and cracks. Replace spring (including wave spring) if distorted or cracked.
10. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Replace all parts that are deeply scored or burred.
11. Check the clutch plates for flatness and fit on the clutch hub serrations. Discard any plate that does not slide freely on the serrations or that is not flat.
12. Check the clutch hub thrust surfaces for scores and clutch hub splines for wear.





13. Remove the direct clutch pack.
1. Remove the retaining ring.
2. Remove the direct clutch pack.





14. Use (A) Clutch Spring Compressor to compress the piston return spring and remove the (B) snap ring.

WARNING: Wear safety glasses when using compressed air.

NOTE: If necessary, use regulated compressed air (207 kPa [30 psi] max pressure) to remove the clutch piston.





15. Remove the support and spring assembly and piston.





16. Remove the inner piston seal.





17. Remove the outer piston seal.


Assembly

NOTE: Lubricate direct clutch piston inner seal and seal protector with petroleum jelly.





1. Position (A) Direct Clutch Lip Seal Protector over the clutch cylinder hub and install the (B) inner piston seal.
^ Install the seal with sealing lip facing down.





2. Install the clutch piston outer seal so that when the piston is installed the sealing lip points toward the bottom of the cylinder.

NOTE: Coat the inner and outer direct clutch piston seals, clutch cylinder sealing area and piston inner sealing area with petroleum jelly.





3. Use (A) Direct Clutch Lip Seal Protector to install the (B) direct clutch piston.
4. Install the piston return spring and retainer assembly.





5. Use (A) Clutch Spring Compressor to compress the piston return spring and install the (B) retaining ring.

NOTE: Before assembly, soak new clutch discs in transmission fluid for 15 minutes.





6. Install the clutch pack retaining ring.
1. Alternate external spline (steel) plates and internal spline (friction) plates, starting with a steel plate and ending with the friction plate.
2. Install the clutch pack retaining ring.





7. Use a (A) feeler gauge to check the clearance between the (B) clutch pack retaining ring and the (C) pressure plate.
If the clearance is not within specifications, install the correct size retaining ring and recheck the clearance.





8. Install the washer and the (B) No. 7 needle bearing on the (A) direct clutch hub and install the direct clutch hub.
^ Install the needle bearing with the black side up, toward the direct clutch hub.

NOTE: Inspect the output shaft bearing surfaces for scores. Inspect the output shaft splines for wear. Inspect all bushings.

CAUTION: Make sure the seals are lapped correctly. Internal damage may occur.





9. Install the two direct clutch seal rings.





10. Install the output shaft hub.
^ Position the output shaft hub.
^ Install the retaining ring.





11. Install the three output shaft seal rings.





12. Install the No. 8 needle bearing on the direct clutch cylinder.

NOTE: Direct clutch cylinder may be installed after the output shaft ring gear is installed to the output shaft hub.





13. Assemble the direct clutch on the output shaft.

NOTE: The yellow dot on the output shaft must be aligned with the yellow dot on the output shaft ring gear.





14. Align the yellow dots on output shaft and the output shaft ring gear and install the ring gear on the output shaft.