Part 1

ASSEMBLY




Figure 1 Install Input Shaft







Use petrolatum on all seals to ease assembly of components.

1. Using an arbor press (2) (Figure 1), install input shaft (1) to input shaft hub (3).




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 Disc 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 assembly (1) (Figure 6) to the OD/Reverse piston/clutch retainer assembly (2).




Figure 7 Install Input Hub Tapered Snap Ring






7. Install input hub tapered snap ring (2) (Figure 7).




Figure 8 Underdrive Clutch Piston

1 - PISTON

8. Install UD clutch piston (1) (Figure 8).




Figure 9 Seal Compressor Installer 5067






9. Install UD piston return spring (1) (Figure 9) and Installer 5067 (2).




Figure 10 Underdrive Clutch Piston, Spring and Retainer







Refer to the exploded view as necessary when performing the following steps. (Figure 10)





Figure 11 UD Return Spring and Retainer






10. Place the UD spring retainer (1) (Figure 11) and snap ring (2) into position.




Figure 12 Install UD Spring Retainer and Snap Ring






11. Using Compressor 5059A (6) (Figure 12) and an arbor press (1), Install the UD spring retainer and snap ring (3), Compress just enough to install snap ring.

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




Figure 13 Install Underdrive Clutch Pack






12. Install the UD clutch pack (1, 2) (Figure 13). Leave out upper disc, until snap ring is installed.




Figure 14 UD Clutch Flat Snap Ring






13. Install the UD clutch flat snap ring (1) (Figure 14) using a screwdriver (2).




Figure 15 Install Last UD Clutch Disc

1 - ONE UNDERDRIVE CLUTCH DISC

14. Install the last UD clutch disc (1) (Figure 15).




Figure 16 OD/UD Reaction Plate

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

15. Place the OD/UD clutch reaction plate (1) (Figure 16) 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 17 Tapered Snap Ring






16. Install the snap ring (1) (Figure 17) 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 18 Seating Tapered Snap Ring






17. Seat tapered snap ring (1) (Figure 18) to ensure proper installation.




Figure 19 Input Clutch Assembly on Pressure Fixture Tool 8391






18. Install input clutch assembly (1) (Figure 19) to the Input Clutch Pressure Fixture Tool 8391 (2).




Figure 20 Set Up Dial Indicator to Measure UD Clutch Clearance






19. Set up dial indicator (1) (Figure 20) on the UD clutch pack (2).




Figure 21 Press Down on UD Clutch Pack and Zero Dial Indicator






20. Using moderate pressure, press down and hold (near indicator) (1) (Figure 21) 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.

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 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.

Underdrive Reaction Plate Thickness:

If necessary, select the proper reaction plate to achieve specifications:




Figure 22 Install Overdrive Clutch Pack






24. Install the OD clutch pack (1, 2) (Figure 22).




Figure 23 Install Waved Snap Ring






25. Install OD pressure plate waved snap ring (1) (Figure 23) using a screwdriver (2).




Figure 24 OD/Reverse Reaction Plate






26. Install the OD/Reverse pressure plate (1) (Figure 24) with large step down (towards OD clutch pack) (2).




Figure 25 Overdrive Clutch Assembly







Refer to the exploded view (Figure 25) as necessary when performing the following steps.





Figure 26 Install Flat Snap Ring






27. Install OD pressure plate flat snap ring (3) (Figure 26) using Compressor 5059A (2) and an Arbor Press (1).