27. Direct/Coast Clutch, Reaction Carrier Assemble

DIRECT/COAST CLUTCH, REACTION CARRIER ASSEMBLE





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 retainer into input housing.





4. Compress coast clutch return spring retainer. Use Coast Clutch Return Spring Compressor Adaptor J41236Clutch Spring Compressor 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 Clutch Spring Compressor Adaptor J41232 and Clutch Spring Compressor 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 of bearing into outer race.
16. Place one end bearing into outer race.
17. While rotating sprag slowly, assemble sprag clutch into sprag outer race. Keep grooved edge up and flat side down.
18. Assemble other end bearing on top of 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.
22. 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 4T40E (RPO MN4) has seven steel and five fiber plates in the direct clutch. The 4T45E (RPO MNS) has six steel and six fiber plates in the direct clutch.





24. Assemble steel and fiber direct clutch plates in the direct clutch using the following stacking sequence beginning with a steel plate:
25. Assemble snap ring in order to retain the input sun shaft and sprag clutch assembly and the direct clutch plates.





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





28. Assemble thrust bearing onto top of reaction carrier shaft and shell assembly.
29. 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.

30. Assemble reaction carrier assembly onto reaction sun gear.





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





34. While holding the input sun gear, grab the splined shaft of the direct/coast clutch housing and verify that the assembly locks when the shaft is turned counter-clockwise.

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





35. Slide Input Shaft Seal Installer Set J41234 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 Input Shaft Seal Installer Protector J41234-2.
37. Repeat above procedure for each seal. Adjust the J41234-1 as necessary for each seal groove.





38. Size seals with Input Shaft Seal Installer Sizer 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.