Underdrive Compounder Assembly - Assembly

ASSEMBLY






CAUTION: Lube seal lips with ATF during installation, Use a twisting motion during installation to prevent seal lips from rolling over.

CAUTION: Do not over stretch. Can cause breakage.

1. Install new seal rings (1) on the low clutch retainer (2).





2. Install the low clutch piston (1) into low clutch retainer.





3. Install the low clutch return spring (1) over the low clutch retainer (2).





4. Install compressor 9725 (1) on return spring (3) and slightly compress.
5. Install the snap ring (4) onto low clutch retainer (2).
6. Release pressure on press, remove Compressor 9725.










7. Install the friction disc's (4) and the separator plates (5).
8. Install the reaction plate (3).
9. Install the snap ring (10).





10. Using a Dial Indicator and air pressure measure the low clutch clearance, the clearance should be 0.48 - 0.76 mm (.019 -.030 in.). Install desired selectable snap ring to achieve correct clearance.





11. Using Installer 6756 (2) and a Press (1) install the underdrive compounder bearing (3) to transfer shaft.





12. Install new seal rings on the transfer shaft.
13. Install the transfer shaft (1) onto the low clutch (2).






NOTE: The selectable shim will determine turning torque.

14. Install the selectable shim (3), transfer gear (2) and the transfer gear nut.





15. Using Holder 9739 (1) tighten transfer gear nut to 271 Nm (200 ft. lbs.).





16. Check turning torque using an inch pound torque wrench. Turning torque should be between 8.0 to 18.0 in-lbs (drag), If more than 18.0 in-lbs (drag) choose a larger shim and recheck turning torque. If less than 8.0 in-lbs (drag) choose a smaller shim and recheck turning torque.
17. Remove transfer gear nut and gear.





18. Install the Bearing Retainer Assembly Remover 9908 (1) onto the low clutch (2).





19. Install the overrunning clutch (1) into the low clutch (2).





20. Install the needle bearing (1) onto the transfer shaft.










21. Install the direct clutch retainer (8) onto the retainer (7).
22. Install the return coil spring (5) onto the balance piston (8).
23. Install the direct clutch piston (7) into the balance piston (8) using the Direct Clutch Piston Guide 9727.





24. Install compressor 8250 (2) over the direct clutch balance piston (3) and place onto a press (1).
25. Compress spring to install the snap ring (4) at the direct clutch balance piston.










26. Install the inner and outer spline frictions (2, 3).
27. Install the number two thrust bearing (9).
28. Install the hub (10).
29. Install the number one thrust bearing (11).
30. Install the selectable reaction plate (12).
31. Install the internal snap ring (1).





32. Install the direct clutch (1) onto the low clutch.





33. Install the split bearing (1) using a small pick (2).





34. Using a Dial Indicator and air pressure measure the direct clutch clearance, the clearance should be 0.95 - 1.41 (0.037- 0.056 in). Install desired selectable reaction plate to achieve correct clearance.





35. Install the sun gear (2) onto the shaft.
36. Install the new retaining clip onto the transfer / underdrive shaft.










37. Inspect the needle bearing in the output hub for any damage.
38. Install the thrust washer (9) on the back side of the annulus gear / on the front side of the output hub.
39. Install the annulus gear (8).
40. Install the thrust washer (7) on the front side of the annulus gear.
41. Install the snap ring (6) that holds the annulus gear.
42. Install the planetary carrier (5).
43. Install the snap ring (4) holding the planetary carrier.





44. Install the helical shim (1).





45. Install the planetary gear set / output hub (1) onto the direct clutch.