56. Rotating Clutch Module Assemble (Assembly)

Rotating Clutch Module Assemble (Assembly)

Tools Required
^ J24204-2 Bar and Stud Assembly
^ J43776 C2 Piston Return Spring Compressor
^ J43777C1 Piston Retune Compressor
^ J44525 C1 Clutch Backplate Selector





1. Install the piston seal rings (1, 2, 3) onto the C2 clutch piston (4).
2. Lubricate the C2 balance piston seal (3) the piston Inside Diameter (ID) and Outside Diameter (OD) and the seal rings (1, 2) with Transjel.





3. Position the rotating clutch housing (2) on the work table so that the rear of the housing is facing up.
4. Install O-ring (1) into the bottom groove on the inner hub of the rotating clutch housing (2).





5. Position the C2 clutch piston (3) on the work table so that the rear of the piston is facing up.
6. Align the C2 balance piston (2) so that the rubber seal is facing down.
7. Install the C2 balance piston (2) onto the C2 clutch piston (3).
8. Lubricate the rubber seals on the C2 balance piston (2) with Transjel.
9. Install the C2 clutch piston (3), with the C2 balance piston (2) attached, into the rotating clutch housing (4).
10. Make sure the C2 clutch piston (3) is seated on the rotating clutch housing (4).
11. Push the C2 balance piston (2) below the retaining ring groove on the rotating clutch housing (4).
12. Install the retaining ring (1) into the rotating clutch housing (4).
13. Make sure the retaining ring (1) is seated completely around the rotating clutch housing (4).





14. Align the C2 piston return spring assembly (2) so that the notches of the spring assemblies are facing and aligned with the tangs of the C2 clutch piston (4).
15. Install the C2 piston return spring assembly (2) into the C2 clutch piston (4).
16. Align the C1 piston housing (1) so that the rear of the housing is facing up.
17. Install the C1 piston housing (1) into the C2 clutch piston (4).





18. Position the rotating clutch housing (8) on the base of J24204-2 (10) so that the rear of the housing is facing up.
19. Install J43776-1 (7) onto the shaft of J24204-2 with the bowl down.
20. Install the retaining ring (6) onto the surface of J43776-2 (7).
21. Install the spring (5) of J43776- onto the shaft of J24204-2.
22. Install J43776-2 (4) onto the shaft of J24204-2.
23. Align a notch of J43776-2 (4) with the ball of the C1 piston housing.
24. Install the J24204-2 ball bearing (3) and washer (2) onto the shaft of J24204-2.
25. Install the J24204-2 wing nut (1) onto the shaft of J24204-2.
26. Compress the C2 piston return spring assembly until the retaining ring groove on the inner hub of the rotating clutch housing (8) is visible.
27. Install the retaining ring (6) into the rotating clutch housing inner hub.
28. Make sure the retaining ring (6) is seated all around the clutch housing (8).
29. Remove all J tools except for the base of J24204-2.





30. Install the C1 piston ID seal ring (1) and the C1 piston OD seal ring (2) onto the C1 clutch piston (3).
31. Lubricate the seal rings with Transjel.





32. Position the rotating clutch housing (3) on the work table so that the rear of the housing is facing up.
33. Align the C1 clutch piston (2) so that the spring indents are facing up.
34. Install the C1 clutch piston (2) into the C1 piston housing (4).
35. Make sure the C1 clutch piston (2) is seated in the C1 piston housing (4).
36. Align the C1 piston return spring assembly (1) so that the springs are facing and aligned with the spring pockets of C1 clutch piston (2).
37. Install the C1 piston return spring assembly (1) into the C1 clutch piston (2).





38. Position the rotating clutch housing (7) on the base of J24204-2 (8) so that the rear of the housing is facing up.
39. Install the retaining ring (6) into the inner hub of the rotating clutch housing.
40. Install J43777 (5) onto the shaft of J24204-2(8).
41. Center J43777 (5) on the C1 piston return spring assembly.
42. Install the J43777 extension (4) onto the shaft of J24204-2.
43. Install the J24204-2 ball bearing (3) and washer (2) onto the shaft of J24204-2.
44. Install the J24204-2 wing nut (1) on the shaft of J24204-2.
45. Compress the C1 piston return spring assembly until the retaining ring groove on the rotating clutch housing inner hub is visible.
46. Install the retaining ring (6) into the rotating clutch housing inner hub.
47. Remove tools J24204-2 and J43777.





48. Position the rotating clutch housing (3) on the work table so that the rear of the housing is facing up.
49. Lubricate the rubber seals on the C1 balance piston (2) with Transjel.
50. Align the C1 balance piston (2) so that the rubber seal is facing down.
51. Install the C1 balance piston (2) between the C1 clutch piston and the C1 piston housing.
52. Press the C1 balance piston (2) into the C1 piston housing until the C1 balance piston is below the retaining ring groove on the C1 piston housing.
53. Install the retaining ring (1).
54. Make sure the retaining ring (1) is seated in its groove.





55. Install 2 butt joint seal rings (4) onto the turbine shaft (3).
56. Position the turbine shaft (3) on the work table so that the rear of the shaft is facing up.
57. Align the rotating clutch housing (2) with the rear of the turbine shaft (3) so that the rear of the clutch housing is facing up.
58. Install the rotating clutch housing (2) onto the rear of turbine shaft (3).
59. Install the retaining ring (1) onto the turbine shaft (3).
60. Make sure the retaining ring (1) is seated completely around the turbine shaft (3).





61. Starting with a C1 clutch reaction plate, alternately install 6 C1 clutch reaction plates (2) and 6 C1 clutch friction plates (1) onto the turbine shaft (3).





62. Align J44525-2 (3) with the turbine shaft so that the countersunk holes of J44525-2 are facing up.
63. Install J44525-2 (3) onto the turbine shaft.
64. Align J44525-1 (2) with the turbine shaft so that the inner ridge of J44525-1 is facing down.
65. Slide the inner ridge of J44525-1 (2) into the turbine shaft retaining ring groove.
66. Align the holes in J44525-1 (2) with the countersunk holes of J44525-2 (3).

Notice: Refer to Fastener Notice in Service Precautions.

67. Hand install 2 bolts (1) of J44525 into the holes of J44525-1 (2).
Tighten the bolts to 4 Nm (48 inch lbs.).





Important: The shift quality of the transmission depends heavily upon selecting the correct C1 clutch backplate.

68. Perform the following for each tab of J44525 (1):
^ Place the flat surface, tabbed end, of J44525 or J44525 (1) onto the top surface of J44525 (3).

Important: At most, 2 of the different tabs will fit into the retaining ring groove.
^ Try to slide the tabbed end of J44525 (1) into the retaining ring groove on the turbine shaft.
^ If a tab fits into the retaining ring groove, record the 4-digit ID number located on the stem of J44525 that is associated with the tab. Refer to Selective Components Specifications to determine the correct backplate.

69. Select a C1 clutch backplate as follows:
^ If no tab of J44525 fits into the retaining ring groove, select the C1 clutch backplate with ID No. 6221 or 8521.
^ If one or more tabs of J44525-3 fit into the retaining ring groove, select the C1 clutch backplate with an ID No. corresponding to the highest number recorded in the previous step.

70. Remove J44525 from the turbine shaft.





71. Align the selected C1 clutch backplate (3) so that the beveled edge of the backplate is facing up.
72. Install the C1 clutch backplate (3) onto the turbine shaft (4).
73. Install the retaining ring (2) onto the turbine shaft (4).
74. Lift the C1 clutch backplate (3) and install the spiral retaining ring (1) into the C1 clutch backplate (3).





Notice: Installing the thrust bearing assembly onto the rear of the turbine shaft in the wrong direction could destroy the transmission. The blue stripe must be visible.

75. Align thrust bearing assembly (2) so that the blue stripe on the thrust bearing assembly is facing away from turbine shaft (3).
76. Install the thrust bearing assembly (2) into the turbine shaft (3).
77. Make sure the blue stripe on the thrust bearing assembly is visible.
78. Center the C1 clutch plates (4).
79. Install the C1 drive hub (1) over the C1 clutch plates (4).
80. Make sure the C1 drive hub (1) has seated on the thrust bearing assembly (2).





Notice: Installing the thrust bearing assembly onto the rear of the C1 drive hub in the wrong direction could destroy the transmission. The blue stripe must be visible.

81. Align thrust bearing assembly (2) so that the blue stripe on the thrust bearing assembly is facing away from C1 drive hub (3).
82. Install the thrust bearing assembly (2) onto the rear of the C1 drive hub (3).
83. Make sure the blue stripe on the thrust bearing assembly is visible.
84. Align the C2 drive hub (1) so that the smaller end is facing up.
85. Install the C2 drive hub (1).





86. Starting with a C2 clutch reaction plate, alternately install 7 C2 clutch reaction plates (2) and 6 C2 clutch friction plates (1) into the rotating clutch housing.





87. Align the tangs of the bronze thrust washer (1) with the holes in the C2 drive hub (2).
88. Install the bronze thrust washer (1) onto the C2 drive hub (2).





89. Align the P1 sun gear (3) so that the gear teeth of the sun gear face the concave face of the P1 drive flange (2).
90. Install the P1 sun gear (3) into the P1 drive flange (2).
91. Make sure the splines are engaged.
92. Hold the sun gear and align the double wide splines of the P1 drive flange (2) with the double wide spaces on the rotating clutch housing (4).
93. Install the P1 sun gear (3) with the P1 drive flange (2) into the rotating clutch housing (4).
94. Install the retaining ring (1) into rotating clutch housing (4).
95. Make sure the retaining ring is seated all the way around the rotating clutch housing.
96. Remove tools J24204-2 and J43777