Part 3

Input Housing and Shaft Assembly

Installation (Continued)

7. Install the 3rd and 4th spring assembly (626) into the 3rd and 4th clutch apply ring (625).
8. Install the forward clutch housing (628) and forward clutch piston (630) into the 3rd and 4th apply ring (625).
9. The forward clutch piston (630) apply legs must be indexed with the 3rd and 4th clutch apply ring (625) legs.

10. Install the J 29883 on the input housing.
11. Install the 3rd and 4th clutch apply ring and the forward housing and piston assembly using the following procedure:
- Hold the assembly by the 3rd and 4th clutch apply ring (625) legs during installation.
- Do not let the forward clutch piston (630) separate from the forward clutch housing.
- Firmly seat the assembly.
12. Remove the J 29883 from the input housing.

13. Inspect the overrun clutch piston (632) for the following conditions:
- Porosity or damage
- Seal damage
- Overrun clutch ball proper operation

14. Install the J 29882 on the input housing.
15. Install the overrun clutch piston (632) into the input housing.
16. Remove the J 29882 from the input housing.

17. Using the J 26744-A, carefully install the overrun clutch piston outer seal.

18. Install the overrun clutch spring (634) assembly.

19. Install the J 23327-1 and the J 25018-A, and compress the overrun clutch spring assembly using J 23456.
20. Install the overrun clutch spring retainer snap ring (635).
21. Remove the J 23327-1 and the J 25018-A.

Input Housing to Output Shaft Seal Installation

Install a new input housing to output shaft seal (636).

Overrun Clutch Installation

1. Inspect the fiber plate assemblies (645B) and the steel plates (645A) for the following defects:
- Damaged tangs
- Delamination
- Excessive wear Wear or heat damage

2. Install the overrun clutch plates into the input housing starting with a steel plate (645B) and alternating with fiber plate assemblies (645A).
3. Index the plates in the input housing with the wide notches remaining open.

4. Install the input sun gear bearing assembly (637) into the input housing.

Forward Clutch Sprag Disassemble

Removal Procedure

1. Remove the overrun clutch hub retaining snap ring (638).
2. Remove the overrun clutch hub (639).
3. Remove the forward sprag clutch inner race and input sun gear assembly (640).

4. Remove the sprag assembly retainer rings (643).
5. Remove the forward sprag assembly from the forward clutch outer race (644).

Forward Clutch Sprag Assemble

Installation Procedure

1. Inspect the forward sprag assembly (642) for the following conditions:
- Wear or damage
- Weak or broken springs
2. Inspect the forward clutch outer race (644) for the following conditions:
- Race wear or damage
- Spline wear
- Surface finish damage
3. Install the forward sprag assembly (642) into the forward clutch outer race (644).

4. Inspect the sprag assembly retainer rings (643) for wear or damage.
5. Install the sprag assembly retainer rings (643) into the forward clutch sprag assembly (644)

6. Inspect the forward sprag clutch inner race and input sun gear assembly (640) for the following conditions:
- Damaged spline or gear teeth ring groove damage
- Surface finish damage
- Loose retainer
- Wear
- Cracks
7. Install the forward sprag clutch inner race and input sun gear assembly (640) into the forward sprag and outer race assembly.

8. Inspect the overrun clutch hub (639) for the following conditions:
- Spline damage
- Plugged lubrication holes
- Damaged tangs
- Cracks
9. Install the overrun clutch hub (639) onto the sprag clutch inner race and input sun gear assembly (640).
10. Install the overrun clutch hub retaining snap ring (638).

Important: If the forward clutch sprag assembly operates backwards, you have installed the sprag backwards. Reassemble the sprag correctly.

11. Test the forward clutch sprag assembly for proper operation.
1. Position the forward clutch sprag assembly with the input sun gear facing up.

Important: The sun gear should only rotate in a counter clockwise direction.

2. Hold the forward sprag clutch outer race with one hand and rotate the input sun gear with the other hand.
12. Install the forward clutch sprag and input sun gear assembly into the input clutch housing.
13. Index the overrun clutch hub into the overrun clutch plates.

Forward Clutch Assemble

1. Inspect the forward clutch waved plate (648), the apply plate (646),the fiber plate assemblies (649B), the steel plates (649A) and the selective backing plate (650) for the following conditions:
- Damaged tangs
- Delamination
- Excessive wear
- Heat damage
- Flatness
- Surface finish damage Burrs and nicks

2. Install the forward clutch apply plate (646).
3. Install the forward clutch waved plate (648).
4. Install the forward clutch steel plates (649A) and alternate with the fiber plate assemblies (649B).
5. Install the forward clutch selective backing plate (650).
6. Install the forward clutch backing plate retainer ring (651)

Forward Clutch Piston Travel Check

1. Use feeler gauges to check the forward clutch plate travel. Check travel between the forward clutch backing plate retainer ring (651) and the forward clutch selective backing plate (650).
2. The forward clutch plate travel should be:
- 245 mm - 0.766- 1.756 mm (0.030-0.069 in)
- 298 mm/300 mm - 0.866-1.876 mm (0.034-0.074 in)
3. Select the proper forward clutch selective backing plate (650) to obtain the correct travel. Refer to Forward Clutch Backing Plate Selection.

Forward Clutch Piston Travel Check

1. Inspect the 3rd and 4th clutch apply plate (653), the fiber plate assemblies (654A), the steel plates (654B) and the selective backing plate (655) for the following conditions:
- Damaged tangs
- Delamination
- Excessive wear
- Heat damage or wear
- Surface finish Flatness

2. Install the 3rd and 4th clutch apply plate (653) into the input housing. Index each leg of the apply plate into the apply ring legs.

Important: Vehicle models with a 2.2L engine have a different clutch plate stack.

3. Install the 3rd and 4th clutch plates starting with a fiber plate assembly (654A) and alternate with a steel plate (654B).
4. The first steel plate (654B) has the same spline configuration as the 3rd and 4th clutch apply plate (653).

Important: Use the following 3rd and 4th clutch plate installation order only for vehicle models with a 2.2L engine.

5. Install the 3rd and 4th clutch plates in the following order:

Important: 3rd and 4th clutch steel plate (652) is thinner than the other steel plates (654B).

1. steel plate (652)
2. fiber plate assembly (654A)
3. steel plate (654B)
4. fiber plate assembly (654A)
5. steel plate (654B)
6. steel plate (654B)
7. fiber plate assembly (654A)
8. steel plate (654B)
9. fiber plate assembly (654A)
10. steel plate (654B)
11. fiber plate assembly (654A)

6. Install the 3-4 clutch boost spring assemblies (600) into the input housing.

7. Install the 3rd and 4th clutch selective backing plate (655). Some models may have a chamfer on one side of the selective backing plate. Install the chamfer side up.
8. Install the 3rd and 4th clutch backing plate retainer ring (656).

3-4 Clutch Plate Travel Check

1. Use feeler gauges to check the 3rd and 4th clutch plate travel.
2. Check the travel between the selective backing plate (655) and the first fiber plate assembly (654A).
The 3rd and 4th clutch plate travel should be 0.90-2.10 mm (0.035-0.083 in).
3. Select the proper 3rd and 4th clutch selective backing plate to obtain the correct travel. Refer to 3rd and 4th Clutch Backing Plate Selection.

Clutch Air Check

Inspection Procedure

Important: When the overrun clutch is checked, the air will blow by the forward clutch piston lip seals and exit out of the forward clutch feed hole in the turbine shaft.

1. Apply air to the feed holes in the turbine shaft in order to check the following items:
- The 3rd and 4th clutch (1)
- The forward clutch (2)
- The overrun clutch (3)

Turbine Shaft Seals Installation

Tools Required
- J 36418-1A Turbine Shaft Seal Installer
- J 36418-2A Turbine Shaft Seal Sizer

1. Use the J 3641 8-1A in order to install the four turbine shaft oil seal rings (619).
2. Place the J 36418-2A over the turbine shaft oil seal rings (619). Leave the J 36418-2A on the shaft until the reverse input clutch must be installed on the input clutch.
1. Remove the pump slide inner (207) and outer (206) springs.
2. Place a rag over the springs while removing them to prevent the springs from flying out.

3. Remove the oil pump rotor (212) and pump vane rings (210).
4. Remove the pump vanes (213).
5. Remove the rotor guide (211).

6. Remove the pump slide (203), pump slide support seal (208) and the pump slide seal (209).
7. Remove the slide seal back-up O-ring seal (202) and the oil seal (slide to wear plate) ring (201).
8. Remove the pivot slide pin (205) and the pivot pin spring (204).