16. Direct Clutch Replacement

Direct Clutch Replacement

^ Tools Required
- J 7872 Magnetic Base Indicator Set
- J 23327 Clutch Spring Compressor
- J 26900-6 Dial Caliper
- J 36850 Transjel Lubricant

Removal Procedure





1. Use a J 7872 in order to measure the direct clutch piston stroke before disassembly.
1. Temporarily install the direct clutch assembly onto the fluid pump (2) and place the J 7872 plunger on the direct clutch piston (1).
2. Apply 392 - 785 kPa (57 - 114 psi) of compressed air into the direct clutch apply passage of the fluid pump and observe the J 7872.
3. The standard direct clutch piston stroke is greater or less than specified, inspect all direct clutch components for excessive wear.
4. Standard direct clutch piston stroke 1.12 - 1.52 mm (0.0441 - 0.0598 inch).





2. Remove the direct clutch snap ring (1) from the direct clutch drum (2).





3. Remove the direct clutch assembly (1) from the forward clutch assembly (2).





4. Remove the forward clutch inner thrust bearing (4) from the center of the forward clutch drum.
5. Remove the direct clutch thrust washer (2) from the top of the forward clutch assembly (3).
6. Remove the forward clutch outer thrust bearing (1) from the top of the forward clutch drum.





7. Remove the following components from the direct clutch drum (1):
^ The direct clutch flange
^ 3 discs
^ 3 plates





8. Use a J 23327 and a hydraulic press in order to remove the direct clutch piston return spring snap ring (1) from the direct clutch piston return spring retainer.





9. Remove the direct clutch piston return springs (2) from the direct clutch piston (1).





10. Important: When using compressed air to remove components, air pressure should not exceed 98 kPa (14 psi).

Remove the direct clutch piston (1) from the direct clutch drum by temporarily installing the direct clutch assembly onto the fluid pump (2). Apply low pressure compressed air into the direct clutch apply passage of the fluid pump.
11. Remove the direct clutch piston seals from the direct clutch piston.
12. Clean all the direct clutch components and dry the components thoroughly.
13. Inspect the direct clutch discs for excessive wear or damage. Replace the components as necessary.
14. Inspect the direct piston for cracks or porosity and replace as necessary.





15. Inspect the direct clutch piston check ball (2) operation by applying compressed air into the working and release sides of the direct clutch piston (1, 3). There must be no air leakage on the working side. Air must pass freely through the release side. If these conditions do not exist, replace the direct clutch piston.
16. Inspect the direct clutch piston return spring for distortion or weakness and replace as necessary.





17. Use the J 26900-6 in order to measure the inside diameter of the direct clutch bushing (1).
^ The maximum inside diameter of the direct clutch bushing is 48.270 mm (1.9004 inch)
^ If the inside diameter of the direct clutch house bushing is greater than specified, replace the direct clutch drum

Installation Procedure

Important: When installing new clutch discs in the 1st-reverse brake, the underdrive brake, the underdrive clutch, the intermediate brake, the forward clutch or the direct clutch assemblies, the new clutch discs MUST be soaked in Dexron III Automatic Transmission Fluid GM P/N 12346143 or equivalent, two hours prior to installation. This causes the clutch material on the discs to permeate with fluid which will aid in ease of assembly and prevent clutch overheating on first time engagement.





1. Install two new direct clutch piston seals (2) onto the direct clutch piston (1).
2. Apply J 36850 to the new direct clutch piston seals.





3. Install the direct clutch piston (2) into the direct clutch drum (1) with the cup side facing upwards.





4. Install the direct clutch piston return springs (1) onto the direct clutch piston (2).





5. Use a J 23327 and a hydraulic press to install the direct clutch piston return spring snap ring (2) onto the direct clutch piston return spring retainer.





6. Important: The direct clutch flange must be installed with the flat side facing down and the stepped portion facing upwards.

Install three discs (2), 3 plates (3) and the direct clutch flange (1) into the direct clutch drum in the following order:
^ 1 plate
^ 1 disc
^ 1 plate
^ 1 disc
^ 1 plate
^ 1 disc
^ The flange
7. Install the direct clutch snap ring into the direct clutch drum.





8. Use a J 7872 in order to measure the direct clutch piston stroke after assembly is complete.
1. Temporarily install the direct clutch assembly (1) onto the fluid pump (2) and place the J 7872 on the direct clutch piston.
2. Apply 392 - 785 kPa (57 - 114 psi) of compressed air into the direct clutch apply passage of the fluid pump and observe the J 7872.
3. The standard direct clutch piston stroke should fall within 1.12 - 1.52 mm (0.0441 - 0.0598 inch).
4. If the direct clutch piston stroke is greater or less than specified, and all direct clutch components exhibit little or no wear, select one of the following direct clutch flange sizes to bring the direct clutch piston stroke within specification:
^ 2.60 mm (0.102 inch)
^ 2.80 mm (0.110 inch)
^ 3.00 mm (0.118 inch)
^ 3.20 mm (0.126 inch)