Direct Clutch Assembly

Direct Clutch Assembly

Special Tool(s):

Special Tool(s):

Material:

Direct Clutch Assembly:

Disassembly
1. Remove and discard the 2 square cut seals and the roller bearing.





2. Remove the upper roller bearing.





3. Remove the direct clutch snap ring.





4. Remove the steel and friction direct clutch plates.





5. Install the special tools onto the direct clutch assembly.





6. Using the special tool, remove the direct clutch return spring retainer.





7. Remove the special tool.





8. Remove the direct clutch return spring washer.





9. Remove the direct clutch return spring.





10. Slightly press down on the balance piston and remove the snap ring.





11. Remove the baffle plate from the direct clutch piston.





12. Remove the direct clutch piston.





13. Remove and discard the outer O-ring seal from the balance piston.





14. Remove and discard the outer and inner O-ring seal from the apply piston.





15. Inspect the direct clutch drum for damage. If damage is indicated, install a new direct clutch drum.

Assembly
1. Install a new inner and outer O-ring seal on the apply piston.





2. Install a new outer O-ring seal on the balance piston.





3. Lightly coat the O-ring seals in clean transmission fluid and install the direct clutch piston.





4. Lightly coat the O-ring seals in clean transmission fluid and install the apply piston into the direct clutch balance piston.





5. Slightly press down on the balance piston and install the snap ring.





6. Install the direct clutch return spring.





7. NOTE: When installing the washer, the stepped edge must face upward.

Install the direct clutch return spring washer.





8. Install the special tool.





9. Using the special tool, install the direct clutch return spring retainer.





10. NOTE: Before assembly, soak the new clutch plates in clean automatic transmission fluid.

Install the new direct clutch plates, starting with the wave spring then a steel plate and alternating between steel and friction plates, and ending with the pressure plate on the top.
11. Install the direct clutch snap ring.





12. Install a new roller bearing.





13. Install the direct clutch assembly into the special tool.





14. With the dial indicator set at zero, lift up on the steel pressure plate so it is against the select fit snap ring. Record this reading as reading A.
15. Rotate the direct clutch assembly 180 degrees from the opening of the snap ring, take a second reading and record this reading as reading B.





16. NOTE: If the final measurement is not within specification, install a new snap ring until the correct specification is achieved.

^ 5.4L engine 0.50-1.30 mm (0.020-0.051 in).
If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is high, remeasure using a thicker select fit snap ring. If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is low, remeasure using a thinner select fit snap ring.
17. Install new square cut seals and roller bearing.