Forward Clutch Assembly

Forward Clutch Assembly

Special Tool(s):

Material:

Forward Clutch Assembly (A Clutch):

Disassembly
1. Remove the sun gear from the forward clutch assembly.
^ With a small screwdriver or a suitable pick inserted into the sun gear push on the retaining ring in 3 places while lifting up on the sun gear to remove.





2. Remove the forward clutch pack snap ring.





3. NOTE: Inspect the forward clutch drum and the friction and steel plates for damage. Install new components as necessary.

Remove and inspect the forward clutch steel and friction plates.





4. NOTE: The bottom of the special tool will need to be installed from the back side of the forward clutch assembly.

Install the special tool under the forward clutch drum.





5. NOTE: The bottom of the special tool will need to be installed from the back side of the forward clutch assembly.

Using the special tool, slightly collapse the balance dam to gain access to the retaining ring. Remove the retaining ring.





6. Prior to removing the balance dam, make an identifying mark on the balance dam and the center part of the housing. This is for correct alignment during the assembly.





7. Remove the balance dam.





8. Remove and discard the O-ring seal from the balance dam.





9. Remove the forward clutch return spring.





10. Install the forward clutch into the front pump to remove the forward clutch piston. Apply a small amount of shop air to remove the piston.





11. Remove and discard the inner and outer piston O-ring seals.





12. Remove the sun gear from the planet assembly.





13. Remove the bearing from the sun gear.





14. Inspect the sun gear and bearing for damage. Install new components as necessary.





Assembly

1. NOTE: If a new planetary assembly is being installed, the new planetary assembly may not come with the snap ring installed.

Install the planetary assembly snap ring, if necessary.





2. Make sure the planetary snap ring is oriented as shown.





3. Install the bearing onto the sun gear.





4. Install the sun gear into the planet assembly with the bearing facing down and the recess part of the gear up.





5. Install new O-ring seals onto the forward clutch piston.





6. Lightly coat the O-ring seals with clean transmission fluid and install the forward clutch piston into the forward clutch drum.





7. Install the forward clutch return spring.





8. Install a new O-ring seal onto the forward clutch balance dam. Lightly coat the O-ring seal with clean transmission fluid.





9. Align the marks made during disassembly and install the balance dam into the forward clutch drum.





10. NOTE: Prior to releasing the special tool, make sure that the snap ring is fully seated.

Using the special tool, slightly collapse the balance dam to install the retaining ring. Install the retaining ring.





11. Install the new forward clutch plates, starting with the wave spring then a steel plate and alternating between friction and steel plates, and ending up with the pressure plate.





12. Install the forward clutch plate snap ring.





13. NOTE: All forward clutch plates friction and steel are of a wave-type design.

Install the forward clutch assembly into the special tool so the dial indicator fits into the opening of the snap ring.





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 forward 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.
^ 4.6L 3V engine - 0.5 - 0.9 mm (0.019 - 0.035 inch)

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 the sun gear and planetary gearset into the forward clutch drum. Make sure it snaps and locks in place.