Input Clutch
Input Clutch
Special tools, testers and auxiliary items required
• Input Clutch Pressure Fixture (8391)
• Compressor (5059A)
• Disc (6057)
• Installer (5067)
Disassembly
- Mount the input clutch assembly (3) to the input clutch pressure fixture (8391).
- Tap down on the reverse clutch reaction plate (4) in order to release pressure from snap ring (2).
- Using a screwdriver, (2) remove the reverse clutch snap ring (3).
- Using screwdrivers (2 and 3), pry up and remove the reverse clutch reaction plate (1).
- Remove the reverse clutch pack (3 clutch discs) and (4 clutch plate).Tag components for assembly identification.
- Remove the OD/reverse pressure plate snap ring (1).
- Remove OD/reverse pressure plate (2).
- Remove OD/reverse pressure plate wave snap ring (3).
- Remove OD clutch pack (4 clutch discs) and (5 clutch plates). Tag components for assembly identification.
- Remove and inspect the overdrive shaft (1), the number three thrust washer plate (2) and washer (3), the underdrive shaft (4) and the number two needle bearing (5).
- Remove the OD/UD reaction plate tapered snap ring (1), clutch plate (5), and first clutch disc (3).
- Remove the UD clutch flat snap ring (4) and the rest of the input clutch assembly (6). Tag clutch pack for assembly identification.
Compress return spring just enough to remove or install snap ring.
- Using compressor (5059A) (4) and an arbor press (2), compress the UD clutch piston/spring enough to remove snap ring (3).
- Remove the spring retainer (2), spring (3), and UD clutch piston (4).
- Using snap ring pliers (3), remove the input hub tapered snap ring (2).
- Tap on the input shaft and hub (1) with a soft faced hammer (2) and separate the input hub from OD/reverse piston and clutch retainer.
- Separate the input clutch retainer (2) from the OD/reverse piston (1).
- Using disc (6057) (4) and an arbor press (1), compress the return OD/reverse piston return spring just enough to remove the snap ring (3).
- Using a sharp pointed tool (2), remove the input shaft (1) to input clutch hub snap ring (3).
- Using a suitably sized socket (2) and an arbor press (1), remove the input shaft (5) from the input shaft hub (7).
Assembly
Use petrolatum based grease on all seals in order to ease assembly of the components.
- Using an arbor press (2), install the input shaft (1) to the input shaft hub (3).
- Using a screwdriver (2), install the input shaft snap ring (3).
- Place the OD/reverse piston (1), return spring (2) and snap ring (3) into position.
- Using an arbor press (1) and disc (6057) (4), compress the OD/reverse piston (5) and return spring (6), just enough to install the snap ring (3) using a screwdriver (2).
- Push down the OD/reverse piston assembly (1) in order to install the input clutch retainer (2).
- Push down on the input hub/shaft assembly (1) (rotate as necessary to align the splines) in order to install the input hub/shaft to the OD/reverse piston/clutch retainer assembly (2).
- Using snap ring pliers (3), install the input hub tapered snap ring (tapered side up with tabs in cavity) (2).
- Install the UD clutch piston (1).
- Install the UD piston return spring (1) and installer (5067) (2).
- Place the UD spring retainer (1) and snap ring (2) into position.
- Using compressor (5059A) (6) and an arbor press (1), install the UD spring retainer and snap ring (3) using snap ring pliers (2). Compress the OD/reverse piston (4) just enough to install the snap ring (3).
Compress return spring just enough to install snap ring.
- Install the UD clutch pack (1, clutch plates) and (3, clutch discs). Leave out the upper disc (2), until the snap ring is installed.
- Using a screwdriver (2), install the UD clutch flat snap ring (1).
- Install the last UD clutch disc (1).
- Place the OD/UD clutch reaction plate (1) and snap ring into position. The OD/UD clutches reaction plate has a step on both sides. Install the OD/UD clutches reaction plate with the tapered step side up.
- Using a screwdriver (2), install the snap ring (1).
• the snap ring (1) ends must be located within one finger of the input clutch hub. Be sure that snap ring is fully seated, by pushing down with screwdriver (2), into the snap ring groove all the way around.
• Do not reuse tapered snap ring (1).
• Do not reuse the tapered snap ring (1).
- Using a screwdriver (2), seat the tapered snap ring (1) to ensure proper installation.
- Install the input clutch assembly (1) to the input clutch pressure fixture (8391) (2).
- Set up the dial indicator (1) on the UD clutch pack (2).
- Using moderate pressure, press down and hold (near the indicator), the UD clutch pack (2) with a screwdriver or suitable tool and zero the dial indicator. When releasing pressure on the clutch pack, the indicator reading should advance to 0.005 to 0.010 in.
Do not apply more than 30 psi (206 kPa) to the underdrive clutch pack.
- Apply 30 psi (206 kPa) to the underdrive hose on input clutch pressure fixture (8391) and measure the UD clutch clearance. Measure and record the UD clutch pack measurement in four places, 90 degrees apart.
- Take the average of the four measurements and compare with the UD clutch pack (2) clearance specification. The underdrive clutch pack clearance must be between 0.91 to 1.47 mm (0.036 to 0.058 in).
- If necessary, select the proper reaction plate to achieve specifications:
- Install the OD clutch pack (four discs/three plates) (1).
- Using a screwdriver (2), install the OD pressure plate waved snap ring (1).
- Install the OD/reverse pressure plate (1) with the large step down (2), towards OD clutch pack.
- Install the OD pressure plate flat snap ring (3).
- Measure the OD clutch pack clearance. Set up the dial indicator (1) on top of the OD/reverse pressure plate.
- Zero the dial indicator and apply 30 psi (206 kpa) of air pressure to the input clutch pressure fixture (8391). Measure and record the OD clutch pack measurement in four places, 90 degrees apart.
- Take average of the four measurements and compare with the OD clutch pack clearance specification. The OD clutch pack clearance is between 0.491 to 2.345 mm (0.019 to.092 in).
If not within specifications, the clutch is not assembled properly. There is no adjustment for the OD clutch clearance.
- Install the reverse clutch pack (two discs (2) and one plate (1).
- Install the reverse clutch reaction plate (1) with the flat side down towards reverse clutch.
- Tap the reaction plate (3) down to allow installation of the reverse clutch snap ring (1) Install reverse clutch snap ring (1).
- Using screwdrivers (1 and 3), pry up the reverse reaction plate (4) in order to seat against the snap ring (2).
- Set up a dial indicator (1) on the reverse clutch pack (2).
- Using moderate pressure, press down and hold (near the indicator) the reverse clutch disc (2) with a screwdriver or suitable tool and zero the dial indicator (1). When releasing pressure, the indicator should advance to (0.005 to 0.010 in.) as the clutch pack relaxes.
- Apply 30 psi (206 kpa) of air pressure to the reverse clutch hose on the input clutch pressure fixture (8391). Measure and record the reverse clutch pack measurement in four places, 90 degrees apart.
- Take the average of the four measurements and compare with the reverse clutch pack clearance specification. The reverse clutch pack clearance is between 0.76 to 1.245 mm (0.030 to 0.049 in). Select the proper reverse clutch snap ring to achieve specifications:
• The number 2 bearing is a light press fit into the clutch hub. There are 5 tabs with dimples that can be pressed in by hand.
- To complete the assembly, the reverse clutch and overdrive clutch must be removed.
- Install the number two needle bearing (1).
- Install the underdrive shaft assembly (1).
- Install the number three thrust washer (1) to the underdrive shaft assembly (2). Be sure the five tabs are seated properly.
- Install the number three thrust plate (3) (note 3 tabs) to the bottom of the overdrive shaft assembly (1). Retain with petrolatum grease or transmission assembly gel (2).
- Install the overdrive shaft assembly (1).
- Reinstall the overdrive and reverse clutch as shown. Retesting these clutch clearances is not necessary.