Overdrive Direct Clutch
OVERDRIVE DIRECT CLUTCH
Components
Overdrive Planetary Gear, Overdrive Direct Clutch And Overdrive One-Way Clutch Disassembly
1. CHECK OPERATION OF ONE-WAY CLUTCH
Hold the Overdrive (O/D) direct clutch drum and turn the input shaft. The input shaft turns freely clockwise and locks counterclockwise.
2. REMOVE O/D DIRECT CLUTCH ASSEMBLY FROM O/D PLANETARY GEAR
a. Remove the O/D direct clutch from the O/D planetary gear.
b. Remove the bearing and race from the planetary carrier.
3. CHECK PISTON STROKE OF O/D DIRECT CLUTCH
a. Place the O/D direct clutch assembly onto the oil pump.
b. Using a dial indicator, measure the O/D direct clutch piston stroke while applying and releasing compressed air (392 - 785 kPa, 4 - 8 kgf/cm2, 57 - 114 psi).
Piston stroke: 1.77 - 2.58 mm (0.0697 - 0.1016 inch)
If the values are nonstandard, inspect the discs.
c. Remove the O/D direct clutch assembly from the oil pump.
4. REMOVE O/D BRAKE HUB
a. Using a screwdriver, remove the snap ring.
b. Remove the O/D brake hub.
5. REMOVE DISC
6. REMOVE FLANGE AND CUSHION PLATE
a. Using a screwdriver, remove the snap ring.
b. Remove the flange and cushion plate.
7. REMOVE PISTON RETURN SPRINGS
a. Place Special Service Tools (SST) on the spring seat and compress the return springs with a shop press.
SST 09350-20015 (09369-20040)
b. Using a snap ring expander, remove the snap ring.
c. Remove the spring seat and 18 springs.
8. REMOVE O/D DIRECT CLUTCH PISTON
a. Place the O/D direct clutch onto the oil pump.
b. Hold the O/D direct clutch piston and apply compressed air to the oil pump to remove the O/D direct clutch piston.
HINT: Make sure the direct clutch piston is square in the drum before applying compressed air.
c. Remove the 2 O-rings from the piston.
9. REMOVE THRUST WASHER
a. Using a screwdriver, remove the snap ring.
b. Remove the thrust washer.
10. REMOVE ONE-WAY CLUTCH ASSEMBLY
11. DISASSEMBLE ONE-WAY CLUTCH
a. Remove the 2 retainers from both sides.
b. Remove the one-way clutch from the outer race.
12. REMOVE THRUST WASHER
Overdrive Planetary Gear And Overdrive Direct Clutch Inspection
1. INSPECT DISC AND FLANGE
Check to see if the sliding surface of the disc and flange are worn or burnt. If necessary, replace them.
HINT:
- If the lining of the disc is peeling off or discolored, or even if parts of the printed numbers are defaced, replace disc.
- Before assembling new disc, soak it in Automatic Transmission Fluid (ATF) for at least 15 minutes.
2. CHECK OVERDRIVE DIRECT CLUTCH PISTON
a. Check that check ball is free by shaking the piston.
b. Check that the valve does not leak by applying low pressure compressed air.
3. CHECK OVERDRIVE DIRECT CLUTCH DRUM BUSHINGS
Using a dial indicator, measure the inside diameter of the clutch drum bushings.
Maximum inside diameter: 23.14 mm (0.9110 inch)
If the inside diameter is greater than the maximum, replace the clutch drum.
4. CHECK OVERDRIVE PLANETARY GEAR BUSHING
Using a dial indicator, measure the inside diameter of the planetary gear bushing.
Maximum inside diameter: 11.27 mm (0.4437 inch)
If the inside diameter is greater than the maximum, replace the planetary gear.
5. MEASURE PLANETARY PINION GEAR THRUST CLEARANCE
Using a feeler gauge, measure the planetary pinion gear thrust clearance.
Standard clearance: 0.20 - 0.50 mm (0.0079 - 0.0197 inch)
If the clearance is non-standard, inspect the planetary gear thrust washer. If necessary, replace the planetary gear assembly.
Overdrive Planetary Gear, Overdrive Direct Clutch And Overdrive One-Way Clutch Assembly
1. INSTALL THRUST WASHER
Install the thrust washer to the overdrive planetary gear, the grooved side facing upward.
2. ASSEMBLE ONE-WAY CLUTCH
a. Install the one-way clutch into the outer race, the open end of the retainers facing upward.
b. Install the 2 retainers to both sides.
3. INSTALL ONE-WAY CLUTCH ASSEMBLY
4. INSTALL THRUST WASHER
a. Install the thrust washer.
b. Using a screwdriver, install the snap ring.
5. INSTALL OVERDRIVE DIRECT CLUTCH PISTON
a. Coat new O-rings with ATF and install them on the O/D direct clutch piston.
b. Place SST on the direct clutch piston.
SST 09350-20015 (09369-20040)
c. Being careful not to damage the O-rings, press in the direct clutch piston into the clutch drum with both hands.
6. INSTALL PISTON RETURN SPRINGS
a. Install the 18 springs and spring seat.
b. Place SST on the spring seat, and compress the return springs with a shop press.
SST 09350-20015 (09369-20040)
c. Install the snap ring with a snap ring expander. Be sure the end gap of the snap ring is not aligned with the spring seat claw.
7. INSTALL CUSHION PLATE AND FLANGE
a. Install the cushion plate.
b. Install flange, the rounded edge facing upward.
c. Install the snap ring. Be sure the end gap of the snap ring is not aligned with the cutout portion of the drum.
8. INSTALL DISC
9. INSTALL O/D BRAKE HUB
a. Install the O/D brake hub.
b. Using a screwdriver, install the snap ring. Be sure the end gap of the snap ring is not aligned with the cutout portion of the drum.
10. CHECK PISTON STROKE OF O/D DIRECT CLUTCH
a. Place the O/D direct clutch assembly onto the oil pump.
b. Using dial indicator, measure the O/D direct clutch piston stroke while applying and releasing compressed air (392 - 785 kPa, 4 - 8 kgf/cm2 , 57 - 114 psi).
Piston stroke: 1.77 - 2.58 mm (0.0697 - 0.1016 inch)
If the piston stroke is less than the limit, parts may have been assembled incorrectly, check and reassemble again.
11. INSTALL O/D DIRECT CLUTCH ASSEMBLY
a. Coat the race and bearing with petroleum jelly and install them onto the O/D planetary gear.
Bearing and race diameter
b. Install the direct clutch assembly onto the O/D planetary gear.
HINT: Mesh the splines of the O/D planetary gear with the flukes of the disc by rotating and pushing the O/D planetary gear.
12. CHECK OPERATION OF ONE-WAY CLUTCH
Hold the O/D direct clutch drum and turn the input shaft. The input shaft turns freely clockwise and locks counterclockwise.