Part 1

ASSEMBLY




Figure 1 Install Input Shaft







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) (Figure 1).




Figure 2 Install Input Shaft Snap Ring






2. Install input shaft snap ring (3) (Figure 2).




Figure 3 Return Spring and Snap Ring






3. Place OD/Reverse piston (1) (Figure 3) return spring (2) and snap ring (3) into position.




Figure 4 Install Snap Ring






4. Using an arbor press (1) (Figure 4) and Disk 6057 (4), install OD/Reverse piston (5) return spring (6) and snap ring (3).




Figure 5 Install OD/Reverse Piston






5. Install the OD/Reverse piston assembly (1) (Figure 5) to the input clutch retainer (2).




Figure 6 Install Input Shaft Hub Assembly






6. Install the input hub/shaft assy. (rotate to align splines) (1) (Figure 6) to the OD/Reverse piston/clutch retainer assy. (2).




Figure 7 Input Clutch Hub, Retainer, and OD/Reverse Piston






7. Refer to the exploded view as necessary when performing the following steps (Figure 7).




Figure 8 Install Input Hub Tapered Snap Ring






8. Install input hub tapered snap ring (tapered side up with tabs in cavity) (2) (Figure 8).




Figure 9 Underdrive Clutch Piston

1 - PISTON

9. Install UD clutch piston (1) (Figure 9).




Figure 10 Seal Compressor Special Tool 5067






10. Install UD piston return spring (1) (Figure 10) and Installer 5067 (2).




Figure 11 Underdrive Clutch Piston, Spring and Retainer






11. Refer to the exploded view as necessary when performing the following steps.




Figure 12 UD Return Spring and Retainer






12. Place the UD spring retainer (1) (Figure 12) and snap ring (2) into position.




Figure 13 Install UD Spring Retainer and Snap Ring






13. Using Compressor 5059A (6) (Figure 13) and an arbor press (1), Install the UD spring retainer and snap ring (3) Compress just enough to install snap ring (3).

CAUTION: Compress return spring just enough to install snap ring.




Figure 14 Underdrive Clutch Pack






14. Install the UD clutch pack (1, 3) (Figure 14). Leave out upper disc (2), until snap ring is installed.




Figure 15 UD Clutch Flat Snap Ring






15. Install the UD clutch flat snap ring (1) (Figure 15).




Figure 16 Install Last UD Clutch Disc

1 - ONE UNDERDRIVE CLUTCH DISC

16. Install the last UD clutch disc (1) (Figure 16).




Figure 17 OD/UD Reaction Plate

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

17. Place the OD/UD clutch reaction plate (1) (Figure 17) 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.




Figure 18 Tapered Snap Ring






18. Install the snap ring (1) (Figure 18) using a screwdriver (2).

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.




Figure 19 Underdrive Clutch Assembly






19. Refer to the exploded view as necessary when performing the following steps (Figure 19).




Figure 20 Seating Tapered Snap Ring






20. Seat tapered snap ring (1) (Figure 20) to ensure proper installation.




Figure 21 Input Clutch Assembly on Pressure Fixture Tool 8391






21. Install input clutch assembly (1) to the Input Clutch Pressure Fixture 8391 (2) (Figure 21).




Figure 22 Set Up Dial Indicator to Measure UD Clutch Clearance






22. Set up dial indicator (1) on the UD clutch pack (2) (Figure 22).




Figure 23 Press Down on UD Clutch Pack and Zero Dial Indicator






23. Using moderate pressure, press down and hold (near indicator) the UD clutch pack (2) with screwdriver or suitable tool and zero dial indicator (Figure 23). When releasing pressure on clutch pack, indicator reading should advance 0.005-0.010.

CAUTION: Do not apply more than 30 psi (206 kPa) to the underdrive clutch pack.

24. Apply 30 psi (206 kPa) to the underdrive hose on Input Clutch Pressure Fixture 8391 and measure UD clutch clearance. Measure and record UD clutch pack measurement in four places, 90� apart.
25. Take average of four measurements and compare with UD clutch pack (2) clearance specification. Underdrive clutch pack clearance must be 0.94-1.50 mm (0.037-0.059 in.).