Overdrive/Direct Clutch Assembly
Overdrive/Direct Clutch Assembly
Disassembly
1. Remove the overdrive clutch snap ring.
2. Remove the overdrive clutch hub and clutch assembly.
3. Remove the bottom overdrive clutch steel plate.
4. Remove the No. 2 rear sun gear thrust bearing.
5. Install the Overdrive Clutch and Balance Piston Service Set 307-589/1 and 2-6 Spring Compressor 307-584/2 on the balance piston. Using a press, compress the overdrive piston return spring.
6. With the overdrive piston return spring compressed, remove the balance piston snap ring.
7. Remove the Overdrive Clutch and Balance Piston Service Set 307-589/1 and the 2-6 Spring Compressor 307-584/2.
8. Remove and discard the balance piston.
9. Remove the overdrive piston return spring.
10. Position the overdrive/direct clutch assembly in the rear cover.
11. Apply air pressure to the overdrive piston port on the rear cover and remove the overdrive piston.
12. Remove the overdrive/direct clutch assembly from the rear cover.
13. Remove and discard the overdrive clutch piston inner seal.
14. Remove and discard the overdrive clutch piston outer seals from the piston.
15. NOTICE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
Install the Overdrive Clutch and Balance Piston Service Set 307-589/2 and the 2-6 Spring Compressor 307-584/2 on the direct clutch cylinder. Using a press, compress the direct clutch piston return spring, and remove the snap ring.
1. Do not contact the overdrive/direct clutch hub and shaft assembly with the direct clutch cylinder.
2. Remove the snap ring.
16. Remove the Overdrive Clutch and Balance Piston Service Set 307-589/2 and the 2-6 Spring Compressor 307-584/2.
17. Remove the direct clutch cylinder.
18. Remove the rear direct clutch piston seal.
19. Remove and discard the direct clutch piston.
20. Remove the direct clutch piston return spring.
21. Remove and discard the direct clutch piston seals.
22. Remove the direct clutch snap ring.
23. Remove the direct clutch pressure plate, clutch assembly and wave spring.
24. Clean and inspect the overdrive/direct clutch hub and shaft assembly for damage. Install new, if necessary.
Assembly
1. Install the direct clutch wave spring.
2. Lubricate the direct clutch pack in clean automatic transmission fluid.
3. Install the direct clutch assembly and pressure plate.
4. Install the direct clutch snap ring.
5. Install new direct clutch piston seals and lubricate the seals with petroleum jelly.
6. Install the direct clutch piston return spring.
7. Lubricate a new direct clutch piston with petroleum jelly and install the piston.
8. Install a new rear direct clutch piston seal and lubricate it with petroleum jelly.
9. Install the direct clutch cylinder.
10. NOTICE: Only compress the direct clutch piston return spring far enough to install the direct clutch cylinder snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
NOTE: Align the tab on the direct clutch cylinder with the slot on the overdrive/direct clutch hub and shaft assembly.
Install the Overdrive Clutch and Balance Piston Service Set 307-589/2 and the 2-6 Spring Compressor 307-584/2 on the direct clutch cylinder. Using a press, compress the direct clutch piston return spring and install the snap ring.
1. Do not contact the overdrive/direct clutch hub and shaft assembly with the direct clutch cylinder.
2. Install the snap ring.
11. Remove the Overdrive Clutch and Balance Piston Service Set 307-589/2 and the 2-6 Spring Compressor 307-584/2 .
12. Install new seals on the overdrive clutch piston and lubricate the seals with petroleum jelly.
13. Install a new overdrive clutch piston inner seal and lubricate the seal with petroleum jelly.
14. Install the overdrive clutch piston in the overdrive/direct clutch hub and shaft assembly and push the overdrive clutch piston in the cylinder by hand using Overdrive Clutch and Balance Piston Service Set 307-589/1.
15. NOTE: Install the overdrive clutch piston return spring so that the holes are facing upward.
Install the overdrive clutch piston return spring.
16. Lubricate the seals on a new balance piston.
17. Install the new balance piston and install the Overdrive Clutch and Balance Piston Service Set 307-589/1 and 2-6 Spring Compressor 307-584/2 on the balance piston.
18. Using a press, compress the overdrive clutch piston return spring and install the snap ring.
19. Remove the Overdrive Clutch and Balance Piston Service Set 307-589/1 and the 2-6 Spring Compressor 307-584/2 from the balance piston.
20. Install the No. 2 rear sun gear thrust bearing.
21. Install the overdrive clutch hub.
22. Lubricate the overdrive clutch pack in clean automatic transmission fluid.
23. Install the overdrive clutch pack assembly and the pressure plate.
24. Install the overdrive clutch pack snap ring.
25. Position the overdrive/direct clutch assembly in the cover assembly, install the Dial Indicator Gauge with Holding Fixture 100-002 or a suitable dial indicator and position the plunger on the overdrive clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the overdrive clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 1.13 mm (0.044 in) and 2.28 mm (0.090 in). If the clearance is out of range, check the overdrive clutch pack for correct installation. If the overdrive clutch pack is correctly installed, install a new overdrive clutch pack.
26. Position the Dial Indicator Gauge with Holding Fixture 100-002 on the direct clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the direct clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.98 mm (0.039 in) and 2.34 mm (0.092 in). If the clearance is out of range, check the direct clutch pack for correct installation. If the direct clutch pack is correctly installed, install a new direct clutch pack.
