Input Clutch Assembly: Assembly

Fig 1: Install Input Shaft

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Use petrolatum on all seals to ease assembly of components.

1. Using an arbor press (2), install input shaft (1) to input shaft hub (3). See Fig 1.
   Fig 2: Install Input Shaft Snap Ring

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   1 - INPUT SHAFT

   2 - SCREWDRIVER (DO NOT SCRATCH BEARING SURFACE)

   3 - SNAP RING

   4 - O-RINGS

   5 - SEALS

2. Install input shaft snap ring (3). See Fig 2.
   Fig 3: Return Spring and Snap Ring

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   1 - OD/REVERSE PISTON

   2 - RETURN SPRING

   3 - SNAP RING

   4 - O-RING

3. Place OD/Reverse piston (1) return spring (2) and snap ring (3) into position. See Fig 3.
   Fig 4: Install Snap Ring

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   1 - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST ENOUGH TO REMOVE OR INSTALL SNAP RING)

   2 - SCREWDRIVER

   3 - SNAP RING

   4 - DISC 6057

   5 - OD/REVERSE PISTON

   6 - RETURN SPRING

4. Using an arbor press (1) and Disc 6057 (4), Install OD/Reverse piston (5) return spring (6) and snap ring (3). See Fig 4.
   Fig 5: Install OD/Reverse Piston

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   1 - PUSH DOWN TO INSTALL OVERDRIVE/REVERSE PISTON

   2 - INPUT CLUTCHES RETAINER

5. Install the OD/Reverse piston assembly (1) to the input clutch retainer (2). See Fig 5.
   Fig 6: Install Input Shaft Hub Assembly

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   1 - PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY (ROTATE TO ALIGN SPLINES)

   2 - OD/REV. PISTON

6. Install the input hub/shaft assy. (1) to the OD/Reverse piston/clutch retainer assembly. (2). See Fig 6.
   Fig 7: Install Input Hub Tapered Snap Ring

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   1 - INPUT SHAFT

   2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN CAVITY)

   3 - SNAP RING PLIERS

7. Install input hub tapered snap ring (2). See Fig 7.
   Fig 8: Underdrive Clutch Piston

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   1 - PISTON

8. Install UD clutch piston (1). See Fig 8.
   Fig 9: Seal Compressor Special Tool 5067

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   1 - PISTON RETURN SPRING

   2 - INSTALLER 5067

   3 - INPUT SHAFT CLUTCHES RETAINER ASSEMBLY

9. Install UD piston return spring (1) and Installer 5067 (2). See Fig 9.
   Fig 10: Underdrive Clutch Piston, Spring and Retainer

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   1 - SNAP RING

   2 - SPRING RETAINER

   3 - SPRING

   4 - UD CLUTCH PISTON

   5 - SEAL, OUTER

   6 - SEAL, INNER

   7 - INPUT CLUTCH ASSEMBLY

   Refer to the exploded view as necessary when performing the following steps. See Fig 10

   Fig 11: UD Return Spring and Retainer

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   1 - UNDERDRIVE SPRING RETAINER

   2 - SNAP RING

   3 - SEAL

   4 - PISTON RETURN SPRING

10. Place the UD spring retainer (1) and snap ring (2) into position. See Fig 11.
    Fig 12: Install UD Spring Retainer and Snap Ring

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    1 - ARBOR PRESS RAM

    2 - SNAP RING PLIERS

    3 - SNAP RING

    4 - OD/REVERSE PISTON

    5 - INSTALLER5067

    6 - COMPRESSOR 5059A

11. Using Compressor 5059A (6) and an arbor press (1), Install the UD spring retainer and snap ring (3) Compress just enough to install snap ring (3). See Fig 12.
    CAUTION: Compress return spring just enough to install snap ring.
    Fig 13: Install Underdrive Clutch Pack

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    1 - CLUTCH DISC

    2 - CLUTCH PLATE

12. Install the UD clutch pack (1,2). See Fig 13. Leave out upper disc, until snap ring is installed.
    Fig 14: UD Clutch Flat Snap Ring

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    1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING

    2 - SCREWDRIVER

13. Install the UD clutch flat snap ring (1) using a screwdriver (2). See Fig 14.
    Fig 15: Install Last UD Clutch Disc

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    1 - ONE UNDERDRIVE CLUTCH DISC

14. Install the last UD clutch disc (1). See Fig 15.
    Fig 16: OD/UD Reaction Plate

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    1 - OD/UD CLUTCH REACTION PLATE (TAPERED STEP SIDE UP)

15. Place the OD/UD clutch reaction plate (1) and snap ring into position. The OD/UD clutches reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up. See Fig 16.
    Fig 17: Tapered Snap Ring

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    1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING

    2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)

16. Install the snap ring (1) using a screwdriver (2). See Fig 17.
    NOTE: 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.
    Fig 18: Seating Tapered Snap Ring

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    1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING

    2 - SCREWDRIVER

17. Seat tapered snap ring (1) to ensure proper installation. See Fig 18.
    Fig 19: Input Clutch Assembly on Pressure Fixture Tool 8391

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    1 - INPUT CLUTCH ASSEMBLY

    2 - INPUT CLUTCH PRESSURE FIXTURE 8391

18. Install input clutch assembly (1) to the Input Clutch Pressure Fixture Tool 8391 (2). See Fig 19.
    Fig 20: Set Up Dial Indicator to Measure UD Clutch Clearance

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    1 - DIAL INDICATOR

    2 - UNDERDRIVE CLUTCH

19. Set up dial indicator (1) on the UD clutch pack (2). See Fig 20.
    Fig 21: Press Down on UD Clutch Pack and Zero Dial Indicator

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    1 - DIAL INDICATOR

    2 - UNDERDRIVE CLUTCH

20. Using moderate pressure, press down and hold (near indicator) (1) the UD clutch pack (2) with screwdriver or suitable tool and zero dial indicator. When releasing pressure on clutch pack, indicator reading should advance 0.005-0.010. See Fig 21.
    CAUTION: Do not apply more than 30 psi (206 kPa) to the underdrive clutch pack.
21. Apply 30 psi (206 kPa) to the underdrive hose on Tool 8391 and measure UD clutch clearance. Measure and record UD clutch pack measurement in four (4) places, 90° apart.
22. Take average of four measurements and compare with UD clutch pack clearance specification. Underdrive clutch pack clearance must be 0.94-1.50 mm (0.037-0.059 in.). 
23. If necessary, select the proper reaction plate to achieve specifications:

    UNDERDRIVE REACTION PLATE THICKNESS
    4659939AB	5.837-5.937 mm (0.230-0.234 in.)
    4659940AB	6.147-6.248 mm (0.242-0.246 in.)
    4659941AB	6.457-6.557 mm (0.254-0.258 in.)

    Fig 22: Install Overdrive Clutch Pack

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    1 - CLUTCH DISC

    2 - CLUTCH PLATE

24. Install the OD clutch pack (1,2). See Fig 22.
    Fig 23: Install Waved Snap Ring

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    1 - OVERDRIVE PRESSURE PLATE WAVED SNAP RING

    2 - SCREWDRIVER

25. Install OD pressure plate waved snap ring (1) using a screwdriver (2). See Fig 23.
    Fig 24: OD/Reverse Reaction Plate

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    1 - OVERDRIVE/REVERSE PRESSURE PLATE

    2 - (STEP SIDE DOWN)

26. Install the OD/Reverse pressure plate (1) with large step down (towards OD clutch pack) (2). See Fig 24.
    Fig 25: Overdrive Clutch Assembly

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    1 - SNAP RING

    2 - OD/REVERSE PRESSURE PLATE

    3 - SNAP RING (WAVE)

    4 - CLUTCH DISC (3)

    5 - CLUTCH STEEL (2)

    6 - INPUT CLUTCH ASSEMBLY

    Refer to the exploded view as necessary when performing the following steps. See Fig 25.

    Fig 26: Install Flat Snap Ring

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    1 - ARBOR PRESS RAM

    2 - COMPRESSOR 5059A

    3 - FLAT SNAP RING

27. Install OD pressure plate flat snap ring (3) using Compressor 5059A (2) and an arbor press (1). See Fig 26.
    Fig 27: Measure OD Clutch Pack Clearance

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    1 - DIAL INDICATOR

    2 - OD/REVERSE REACTION PLATE

28. Measure OD clutch pack clearance. Set up dial indicator (1) on top of the OD/Reverse pressure plate (2). See Fig 27.
29. Zero dial indicator and apply 30 psi (206 kPa) air pressure to the overdrive clutch hose on Input Clutch Pressure Fixture 8391. Measure and record OD clutch pack measurement in four (4) places, 90° apart.
30. Take average of four measurements and compare with OD clutch pack clearance specification. The overdrive (OD) clutch pack clearance is 1.07-3.25 mm (0.042-0.128 in.). 

    If not within specifications, the clutch is not assembled properly. There is no adjustment for the OD clutch clearance.

    Fig 28: Install Reverse Clutch Pack

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    1 - REVERSE CLUTCH PLATE

    2 - REVERSE CLUTCH DISCS

31. Install reverse clutch pack (two frictions/one steel) (1,2). See Fig 28.
    Fig 29: Install Reaction Plate

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    1 - REVERSE CLUTCH REACTION PLATE (FLAT SIDE DOWN)

32. Install reverse clutch reaction plate with the flat side down towards reverse clutch (1). See Fig 29.
    Fig 30: Reverse Clutch Assembly

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    1 - SNAP RING

    2 - REACTION PLATE

    3 - CLUTCH DISC (2)

    4 - CLUTCH PLATE (1)

    5 - INPUT CLUTCH ASSEMBLY

    Refer to the exploded view as necessary when performing the following steps. See Fig 30.

    Fig 31: Install Reverse Clutch Snap Ring

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    1 - REVERSE CLUTCH SNAP RING (SELECT)

    2 - SCREWDRIVER

    3 - REVERSE CLUTCH REACTION PLATE

33. Tap reaction plate (3) down to allow installation of the reverse clutch snap ring (1). Install reverse clutch snap ring (1). See Fig 31.
    Fig 32: Pry Up Reaction Plate

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    1 - SCREWDRIVER

    2 - SNAP RING

    3 - SCREWDRIVER

    4 - MUST RAISE REVERSE REACTION PLATE TO RAISE SNAP RING

34. Pry up reverse reaction plate (1,3 and 4) to seat against snap ring (2). See Fig 32.
    Fig 33: Measure Reverse Clutch Pack Clearance

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    1 - DIAL INDICATOR

    2 - REVERSE CLUTCH

35. Set up a dial indicator (1) on the reverse clutch pack (2). See Fig 33.
    Fig 34: Press Down on Reverse Clutch and Zero Indicator

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    1 - DIAL INDICATOR

    2 - REVERSE CLUTCH

36. Using moderate pressure, press down and hold (near indicator) reverse clutch disc (2) with screwdriver or suitable tool and zero dial indicator (1). When releasing pressure, indicator should advance 0.005-0.010. as clutch pack relaxes. See Fig 34.
37. Apply 30 psi (206 kPa) air pressure to the reverse clutch hose on Input Clutch Pressure Fixture 8391. Measure and record reverse clutch pack measurement in four (4) places, 90° apart.
38. Take average of four measurements and compare with reverse clutch pack clearance specification. The reverse clutch pack clearance is 0.89-1.37 mm (0.035-0.054 in.).  Select the proper reverse clutch snap ring to achieve specifications:

    REVERSE CLUTCH SNAP RING THICKNESS
    4377195	1.53-1.58 mm (0.060-0.062 in.)
    4412871	1.77-1.83 mm (0.070-0.072 in.)
    4412872	2.02-2.07 mm (0.080-0.082 in.)
    4412873	2.27-2.32 mm (0.090-0.091 in.)

    Fig 35: Install No. 2 Needle Bearing

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    1 - #2 NEEDLE BEARING (NOTE 3 SMALL TABS)

    2 - TABS UP

39. To complete the assembly, reverse clutch and overdrive clutch must be removed.
40. Install the #2 needle bearing (1) (tabs up) (2). See Fig 35.
    Fig 36: Install Underdrive Shaft Assembly

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    1 - UNDERDRIVE SHAFT ASSEMBLY

    2 - #2 NEEDLE BEARING

41. Install the underdrive shaft assembly (1). See Fig 36.
    Fig 37: Install No. 3 Thrust Washer

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    1 - #3 THRUST WASHER (NOTE 5 TABS)

    2 - UNDERDRIVE SHAFT ASSEMBLY

42. Install the #3 thrust washer (1) to the underdrive shaft assembly (2). Be sure five tabs are seated properly. See Fig 37.
    Fig 38: Install No. 3 Thrust Plate

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    1 - OVERDRIVE SHAFT ASSEMBLY

    2 - DABS OF PETROLATUM (FOR RETENTION)

    3 - #3 THRUST PLATE (NOTE 3 TABS)

43. Install the #3 thrust plate (note 3 tabs) (3) to the bottom of the overdrive shaft assembly (1). Retain with petrolatum or transmission assembly gel (2). See Fig 38.
    Fig 39: Underdrive Clutch Assembly

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    1 - SNAP RING (TAPERED)

    2 - OD/UD REACTION PLATE

    3 - CLUTCH DISC (3)

    4 - SNAP RING (FLAT)

    5 - CLUTCH PLATE (3)

    6 - INPUT CLUTCH ASSEMBLY

    Refer to the exploded view as necessary when performing the following steps. See Fig 39.

    Fig 40: Install Overdrive Shaft Assembly

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    1 - OVERDRIVE SHAFT ASSEMBLY

    2 - #3 THRUST PLATE

    3 - #3 THRUST WASHER

44. Install the overdrive shaft assembly. See Fig 40.
45. Reinstall overdrive and reverse clutch as shown in illustration. Rechecking these clutch clearances is not necessary.