Intermediate Brake and Direct Clutch Drum Assembly

Intermediate Brake and Direct Clutch Drum Assembly

Disassembly

1. NOTE: The retaining ring is a select fit. See assembly procedure if installation of new ring or clutch pack is required.

Remove the direct clutch retaining ring and the direct clutch pressure plate.

1. Remove the direct clutch retaining ring.

2. Remove the direct clutch pressure plate.

2. NOTE: Clutch plates are directional. Note the direction of the grooves for installation.

Remove the direct clutch disc pack.

- Inspect and install new steel and friction plates if worn, damaged or overheated.

- Measure and record the thickness of the steel plates for assembly.

3. WARNING: While removing or installing the retaining ring, slowly release tool pressure on clutch piston springs. Failure to follow this instruction may cause the assembly to separate forcefully, resulting in serious personal injury.

NOTICE: Do not fully compress the Clutch Spring Compressor or damage to the spring retainer may occur.

Using the Clutch Spring Compressor, remove the direct clutch piston retaining ring.

4. Relieve the direct clutch spring tension and remove the Clutch Spring Compressor.

5. Remove the direct clutch piston spring retainer and the 20 direct clutch piston springs.

1. Lift the direct clutch piston spring retainer off the direct clutch piston springs.

2. Remove the direct clutch piston springs.

6. WARNING: When using compressed air, never let air pressure exceed 138 kPa (20 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.

Using compressed air, remove the direct clutch piston from the intermediate brake and direct clutch drum.
- Apply air pressure to the hole in the drum while blocking the other.

7. Remove the direct clutch piston inner and outer seal.

1. Remove the direct clutch piston inner seal.

2. Remove the direct clutch piston outer seal.

Assembly

1. NOTICE: The lip seals must be positioned as shown. Care must be taken to prevent rollover or damage of the lip seal.

NOTE: Use new seals to help prevent seal failures.

Install the new direct clutch piston inner seal and the direct clutch piston outer seal.

2. NOTE: Lubricate the direct clutch piston inner and outer seals with transmission fluid.

Install the direct clutch piston into the Piston Seal Sizer.

3. Inspect the intermediate brake and direct clutch drum and components for the following:
- Intermediate brake and direct clutch band surface for scoring.

- Clutch piston bore and the piston inner and outer bearing surfaces for scoring.

- The fluid passages for obstructions. All fluid passages must be clean and free of foreign material.

- Inspect the clutch plates for wear, scoring and fit on the clutch hub serrations.

- Inspect the direct clutch pressure plate for scores on the clutch plate bearing surface. Check the clutch release springs for distortion.

- Verify that the intermediate brake and direct clutch drum check ball is clean and free of foreign material.

4. Carefully remove the direct clutch piston from the Piston Seal Sizer.

5. NOTICE: Care must be taken to prevent damage to the seals during installation.

Install the direct clutch piston.

1. Position the direct clutch piston in the intermediate brake and direct clutch drum.

2. Push down evenly around the piston circumference.

6. Install the direct clutch piston spring retainer and the 20 direct clutch piston springs.

1. Install the direct clutch piston springs.

2. Place the direct clutch piston spring retainer on the direct clutch piston springs.

7. WARNING: While removing or installing the retaining ring, slowly release tool pressure on clutch piston springs. Failure to follow this instruction may cause the assembly to separate forcefully, resulting in serious personal injury.

NOTICE: Do not fully compress the Clutch Spring Compressor or damage to the spring retainer may occur.

Using the Clutch Spring Compressor, install the direct clutch piston retaining ring.

8. Relieve the direct clutch spring tension and remove the Clutch Spring Compressor.

9. NOTICE: The direct clutch friction plates are directional and must be installed with grooves pointing clockwise (ID to OD) and the word TOP facing up. Improper installation can result in transmission damage.

NOTE: If new plates are used, they should be soaked in transmission fluid before assembly.

When installing new friction plates, the word TOP should face up. If reusing plates, grooves must be installed clockwise. Install the direct clutch disc pack.

10. NOTE: If new steel plates are being installed, make sure to use the correct steel plates. Use 2.14 mm (0.08 in) steel plates.

Install the steel clutch plates and friction clutch plates in alternating order starting with a steel clutch plate.

11. NOTE: The retaining ring is a select fit.

Install the direct clutch pressure plate.

1. Install the direct clutch pressure plate.

2. Install the original direct clutch retaining ring on the direct clutch disc pack.

12. WARNING: When using compressed air, never let air pressure exceed 138 kPa (20 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: The direct clutch piston must apply with air pressure and release when the air is removed.

Check the operation using compressed air.
- Apply air pressure to the hole in the drum while blocking the other hole with a finger.

13. Push down on the direct clutch disc pack and check the gap between the direct clutch retaining ring and the direct clutch pressure plate with a feeler gauge.
- If specifications do not match, use a select fit direct clutch retaining ring to match specifications and verify with a feeler gauge.

Direct Clutch