Output Shaft and Direct Clutch Cylinder

Output Shaft and Direct Clutch Cylinder









Output Shaft and Hub Disassembled View










Direct Clutch Disassembled View









Disassembly

1. NOTE: The index mark on the output shaft must be aligned with the index mark on the output shaft ring gear during the assembly procedure.

Remove the ring gear snap ring.





2. Separate the ring gear and output shaft.





3. Remove the 3 output shaft seal rings.





4. Remove the output shaft hub snap ring and the output shaft hub.





5. Remove the 2 direct clutch seal rings.





6. Remove the No. 7 direct clutch inner bearing support.

1. Remove the direct clutch hub.

2. Remove the No. 7 direct clutch inner bearing.

3. Remove the direct clutch inner support.





7. Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with a crocus cloth. Install a new clutch cylinder if badly scored or damaged.

8. Check the fluid passages in the clutch cylinder for obstructions. Clean out all fluid passages. Inspect the clutch piston for scores and install new if necessary. Inspect the check balls for freedom of movement and correct seating.

9. Check clutch release spring for distortion and cracks. Install a new spring (including wave spring) if distorted or cracked.

10. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Install new parts if they are deeply scored or burred.

11. Check the clutch plates for flatness and fit on the clutch hub serrations. Discard any plate that does not slide freely on the serrations or that is not flat.

12. Check the clutch hub thrust surfaces for scores and clutch hub splines for wear.

13. Remove the direct clutch pack.

1. Remove the selective retaining ring.

2. Remove the direct clutch pressure plate.

3. Remove the direct clutch pack friction and steels.





14. Using the Clutch Spring Compressor, compress the piston return spring and remove the snap ring.





15. WARNING: When using compressed air, never let air pressure exceed 172 kPa (25 psi) and always wear safety glasses. Compressed air may cause foreign material or parts to become airborne. Failure to follow this instruction may result in serious personal injury.

NOTE: If necessary, use regulated compressed air 172 kPa (25 psi) maximum pressure to remove the clutch piston.

Remove the support and spring assembly and piston.





16. Remove the inner piston seal.





17. Remove the outer piston seal.





Assembly

1. NOTE: Lubricate the direct clutch piston inner seal and seal protector with petroleum jelly.

Using the Piston Seal Protector, install the inner piston seal.

- Install the seal with sealing lip facing down.





2. Install the clutch piston outer seal so that when the piston is installed, the sealing lip points toward the bottom of the cylinder.





3. NOTE: Coat the inner and outer direct clutch piston seals, clutch cylinder sealing area and piston inner sealing area with petroleum jelly.

Using the Transmission Direct Clutch Outer Fluid Seal Protector, install the direct clutch piston.





4. Install the piston return spring and retainer assembly.

5. Using the Clutch Spring Compressor, compress the piston return spring and install the retaining ring.





6. NOTE: Before assembly, soak new clutch discs in transmission fluid.

Install the direct clutch pack.

1. Install the direct clutch plates.
- Alternate external spline (steel) plates and internal spline (friction) plates, starting with a steel plate and ending with the friction plate.

2. Install the direct clutch pressure plate.

3. Install the clutch pack retaining ring.





7. Use a feeler gauge to check the clearance between the clutch pack selective retaining ring and the pressure plate.
- If the clearance is not within specifications, install the correct size retaining ring and recheck the clearance.










8. Install the direct clutch hub.

1. Install the No. 7 direct clutch inner support with step side down.

2. Install the No. 7 direct clutch bearing with the black marking up.

3. Install the direct clutch hub.





NOTE: Inspect the output shaft bearing surfaces for scores. Inspect the output shaft splines for wear. Inspect all bushings.

9. Using the Teflon Seal Installer, install the first direct clutch seal ring.





10. Using the Teflon Seal Installer, install the second direct clutch seal ring.





11. After both new seals have been installed, use the Teflon Seal Installer to size the seals.





12. Install the output shaft hub.
- Position the output shaft hub.

- Install the retaining ring.





13. Install the 3 output shaft seal rings.





14. Install the No. 8 needle bearing on the direct clutch cylinder.





15. NOTE: Direct clutch cylinder may be installed after the output shaft ring gear is installed to the output shaft hub.

Assemble the direct clutch on the output shaft.





16. NOTE: The index mark on the output shaft must be aligned with the index mark on the output shaft ring gear.

Align the index marks on output shaft and the output shaft ring gear and install the ring gear on the output shaft.