Rear Clutch
CLUTCH-REARDISASSEMBLY
1. Remove fiber thrust washer (18) from forward side of clutch retainer (1).
2. Remove input shaft front and rear seal rings (2).
3. Remove selective clutch pack snap-ring (10).
4. Remove the reaction plate (11), clutch discs (9), steel plates (12), pressure plate (8), wave spring (13), spacer ring (14), and piston spring (7).
5. Remove clutch piston (15) with rotating motion.
6. Remove and discard piston seals (6, 16).
7. Remove input shaft retaining ring (19). It may be necessary to press the input shaft in slightly to relieve tension on the retaining ring
8. Press input shaft out of retainer with shop press and suitable size press tool. Use a suitably sized press tool to support the retainer as close to the input shaft as possible.
CLEANING
Clean the clutch components with solvent and dry them with compressed air. Do not use rags or shop towels to dry any of the clutch parts. Lint from such materials will adhere to component surfaces and could restrict or block fluid passages after assembly.
INSPECTION
Replace the clutch discs if warped, worn, scored, burned/charred, the lugs are damaged, or if the facing is flaking off. Replace the top and bottom pressure plates if scored, warped, or cracked. Be sure the driving lugs on the pressure and clutch plates are also in good condition. The lugs must not be bent, cracked or damaged in any way.
Replace the piston spring and wave spring if either part is distorted, warped or broken.
Check the lug grooves in the clutch retainer. The clutch and pressure plates should slide freely in the slots. Replace the retainer if the grooves are worn or damaged. Also check action of the check balls in the retainer and piston. Each check ball must move freely and not stick.
Replace the retainer bushing if worn, scored, or doubt exists about bushing condition.
Inspect the piston and retainer seal surfaces for nicks or scratches. Minor scratches can be removed with crocus cloth. However, replace the piston and/or retainer if the seal surfaces are seriously scored.
Check condition of the fiber thrust washer and metal output shaft thrust washer. Replace either washer if worn or damaged.
Check condition of the seal rings on the input shaft and clutch retainer hub. Replace the seal rings only if worn, distorted, or damaged. The input shaft front seal ring is teflon with chamfered ends. The rear ring is metal with interlocking ends.
Check the input shaft for wear, or damage. Replace the shaft if worn, scored or damaged in any way.
ASSEMBLY
1. Soak clutch discs in transmission fluid while assembling other clutch parts.
2. Install new seal rings on clutch retainer hub and input shaft if necessary.
a. Be sure clutch hub seal ring is fully seated in groove and is not twisted.
3. Lubricate splined end of input shaft and clutch retainer with transmission fluid. Then partially press input shaft (1) into retainer (2). Use a suitably sized press tool to support retainer as close to input shaft as possible.
4. Install input shaft retaining ring.
5. Press the input shaft the remainder of the way into the clutch retainer.
6. Install new seals (6, 16) on clutch piston (15). Be sure lip of each seal faces interior of clutch retainer.
7. Lubricate lip of piston seals with generous quantity of Mopar(R) Door Ease. Then lubricate retainer (1) hub and bore with light coat of transmission fluid.
8. Install clutch piston (15) in retainer (1). Use twisting motion to seat piston in bottom of retainer. A thin strip of plastic (about 0.020" thick), can be used to guide seals into place if necessary.
CAUTION: Never push the clutch piston straight in. This will fold the seals over causing leakage and clutch slip. In addition, never use any type of metal tool to help ease the piston seals into place. Metal tools will cut, shave, or score the seals.
9. Install piston spring (7) in retainer (1) and on top of piston (15). Concave side of spring faces downward (toward piston).
10. Install the spacer ring (14) and wave spring (13) into the retainer. Be sure spring is completely seated in retainer groove.
11. Install pressure plate (8). Ridged side of plate faces downward (toward piston) and flat side toward clutch pack.
12. Install first clutch disc (9) in retainer on top of pressure plate. Then install a clutch plate (12) followed by a clutch disc until entire clutch pack is installed (4 discs and 3 plates are required) .
13. Install the reaction plate (11).
14. Install selective snap-ring (10). Be sure snap-ring is fully seated in retainer groove.
15. Using a suitable gauge bar (6) and dial indicator (1), measure clutch pack clearance.
a. Position gauge bar across the clutch drum (5) with the dial indicator pointer on the pressure plate (2).
b. Using two small screw drivers, lift the pressure plate and release it.
c. Zero the dial indicator.
d. Lift the pressure plate until it contacts the snap-ring and record the dial indicator reading.
Clearance should be 0.635 - 0.914 mm (0.025 - 0.036 inch). If clearance is incorrect, steel plates, discs, selective snap ring and pressure plates may have to be changed.
The selective snap ring thicknesses are:
^ 0.107 - 0.109 inch
^ 0.098 - 0.100 inch
^ 0.095 - 0.097 inch
^ 0.083 - 0.085 inch
^ 0.076 - 0.078 inch
^ 0.071 - 0.073 inch
^ 0.060 - 0.062 inch
16. Coat rear clutch thrust washer (2) with petroleum jelly and install washer over input shaft and into clutch retainer (1). Use enough petroleum jelly to hold washer in place.