32. Direct/Coast Clutch, Reaction Carrier Assemble

Tools Required
- J23327 Clutch Spring Compressor
- J41232 Direct Clutch Return Spring Compressor Adapter
- J41234-1 Input Shaft Seal Installer Pusher
- J41234-2 Input Shaft Seal Installer Protector
- J41234-3 Input Shaft Seal Installer Sizer
- J41236 Coast Clutch Return Spring Compressor Adapter





1. In order to aid in assembly, lubricate seal with transaxle fluid.
2. Assemble coast clutch piston and seal assembly into input housing.

IMPORTANT: The spring retainer must be assembled with inner lip facing up.

3. Assemble coast clutch release spring and spring retainer into input housing.





4. Compress coast clutch return spring retainer. Use J41236 and J23327.
5. Assemble coast clutch spring retainer snap ring onto input housing.
6. Remove J41236 and J23327.





7. In order to aid in assembly, lubricate seal with transaxle fluid.
8. Assemble direct clutch piston and seal assembly into input housing.
9. Assemble direct clutch return spring assembly into input housing with snap ring retaining tabs facing up.





10. Compress direct clutch spring assembly. Use J41232 and J23327.
11. Assemble direct clutch snap ring into input housing.
12. Remove J41232 and J23327.





IMPORTANT: Assemble steel plates in a position that allows them to drop down onto piston.

13. Assemble four steel coast clutch plates and four new fiber coast clutch plates into input housing in alternating order, beginning with a steel plate.





14. Place sprag outer race on bench with flat side down and side with snap ring groove up.
15. Place one end bearing into outer race.
16. While rotating sprag slowly, assemble sprag clutch into sprag outer race. Keep grooved edge up and flat side down.
17. Assemble other end bearing on top of sprag clutch.
18. Assemble snap ring into sprag outer race in order to retain sprag clutch and end bearings.

IMPORTANT: Snap ring side of assembly faces up when installing sprag clutch onto input sun gear shaft. The flat side of sprag outer race functions as a backing plate for coast clutch.

19. While rotating input sun gear shaft clockwise in order to help seat sprags, assemble sprag clutch and outer race assembly onto input sun gear shaft.





IMPORTANT: The input sun gear shaft must only rotate clockwise.

20. Verify correct operation of sprag clutch by holding sprag clutch outer race and rotating input sun gear shaft.





21. Assemble thrust bearing on underside of input sun gear shaft.
22. Retain thrust bearing with petroleum jelly.
23. Assemble input sun gear shaft and sprag clutch assembly into input housing. The splines on the input sun gear shaft engage with the coast clutch fiber plates.





IMPORTANT: The 4T45E (MN5) transaxle has six steel and six fiber plates in the direct clutch. The 4T40E (MN4) has five steel and five fiber plates in the direct clutch.

24. Assemble steel and new fiber direct clutch plates into input housing in alternating order beginning with a steel plate.
25. Assemble direct clutch backing plate onto input housing with flat side down.
26. Assemble snap ring in order to retain the input sun shaft and sprag clutch assembly and the direct clutch plates.





27. Assemble thrust bearing on top of sprag clutch assembly. Retain with petroleum jelly.
28. Assemble reaction carrier shaft and shell assembly onto input housing. The splines on inside of shell engage the direct clutch fiber plates.





29. Assemble thrust bearing onto top of reaction carrier shaft and shell assembly.
30. Assemble reaction carrier sun gear and shell assembly onto reaction shaft shell.

IMPORTANT: Rotate reaction carrier during assembly in order to mesh sun gear with pinion gears.

31. Assemble reaction carrier assembly onto reaction sun gear.





32. Assemble reaction carrier assembly-to-input sun gear thrust bearing onto reaction carrier assembly.
33. Assemble input sun gear onto input sun gear shaft.
34. Assemble input sun gear snap ring onto input sun gear shaft.





IMPORTANT: When assembling new Teflon(TM) seals onto the input shaft, begin with seal closest to housing.

35. Slide J41234-1 over the input shaft, and position J41234-1 at seal groove closest to housing. Coat the J41234-1 with transaxle fluid.
36. Guide a new seal onto J41234-1 and slide seal into seal groove with J41234-2.
37. Repeat above procedure for each seal. Adjust the J41234-1 as necessary for each seal groove.





38. Size seals with J41234-3.
39. Leave J41234-3 in place for at least five minutes. If possible, leave J41234-3 in place until the assembly is installed into the transaxle case.