Underdrive Compounder
Underdrive Compounder
Special tools, testers and auxiliary items required
• Compressor (8250)
• Puller Adapter (9908)
• Compressor (9725)
• Installer (6756)
• Gear Holder (9739)
• Direct Clutch Piston Guide (9727)
• Kukko Puller (15-3)
Disassembly
- Remove the planetary gear set/output hub (1).
- Remove the helical shim (1).
- Remove the snap ring (4) holding the planetary carrier.
- Remove the planetary gear carrier (5).
- Remove the snap ring (6) holding the annulus gear.
- Remove the needle bearing (7) on the front side of the annulus gear.
- Remove the annulus gear (8).
- Remove the needle bearing (9) on the back side of the annulus gear/on the front side of the output hub.
- Inspect the needle bearing in the output hub for any damage.
- Using two small picks (1), remove the retaining clip from the transfer/underdrive shaft.
• A new retaining clip will be used during assembly.
- Discard the retaining clip (1) (that was removed from the transfer/underdrive shaft.
- Remove the sun gear (2) from the shaft.
- Remove the split bearing (1) using a small pick (2).
- Remove the direct clutch (1) from the low clutch.
- Remove the internal snap ring (1).
- Remove the selectable reaction plate (12).
- Remove the number one thrust bearing (11).
- Remove the hub (10).
- Remove the number two thrust bearing (9).
- Remove the inner and outer spline frictions (2 and 3).
- Install compressor (8250) (2) over the direct clutch balance piston (3) and place onto a arbor press (1).
- Compress the spring in order to remove the snap ring (4) for the direct clutch balance piston (3).
- Remove the direct clutch balance piston (8).
- Remove the return coil spring (5).
- Remove the direct clutch piston (7) from the retainer (6).
- Remove the needle bearing (1) from the transfer shaft.
- Remove the overrunning clutch (1) from the low clutch (2).
- Remove the puller adapter (9908) (1) from the low clutch (2).
- Remove the transfer shaft (1) from the low clutch (2).
- Using kukko puller (15-3) (2) and a press (3) remove the underdrive compounder bearing (1).
- Remove the snap ring (10).
- Remove the reaction plate (3).
- Remove the friction disc's (4) and the separator plates (5).
- Install compressor (9725) (1) onto the return spring (3) and compress slightly.
- Remove the snap ring (4) from low clutch retainer (2).
- Release the pressure on the press and remove compressor (9725) and the return spring (1).
- Remove the low clutch piston (1) from low clutch retainer (2). Low air pressure may be applied to the low clutch retainer port (3) in order to move the piston out of the bore.
- Remove the seal rings (1) from the low clutch retainer (2).
Assembly
• Lube the seal lips with ATF during installation, Use a twisting motion during installation to prevent the seal lips from rolling over.
• Do not overstretch. Overstretching can cause breakage.
- Install NEW seal rings (1) onto the low clutch retainer (2).
- Install the low clutch piston (1) into low clutch retainer (2).
- Install the low clutch return spring (1) over the low clutch retainer (2).
- Install compressor (9725) (1) onto the return spring (3) and compress slightly.
- Install the snap ring (4) onto low clutch retainer (2).
- Release the pressure on the press, remove compressor (9725).
- Install the friction discs (4) and the separator plates (5).
- Install the reaction plate (3).
- Install the snap ring (10).
- Using a dial indicator and air pressure measure the low clutch clearance, the clearance should be between 0.48 to 0.76 mm (.019 to.030 in). Install the desired selectable snap ring in order to achieve the correct clearance.
- Using installer (6756) (2) and a arbor press (1), install the underdrive compounder bearing (3) to the transfer shaft.
- Install new seal rings onto the transfer shaft.
- Install the transfer shaft (1) onto the low clutch (2).
• The selectable shim will determine the turning torque.
- Install the selectable shim (3), transfer gear (2) and the transfer gear nut.
- Using gear holder (9739) (1) tighten the transfer gear nut to 271 Nm (200 ft lbs).
- Test the turning torque using an inch pound torque wrench. The turning torque should be between 8.0 to 18.0 in-lbs of drag, If more than 18.0 in-lbs of drag, choose a larger shim and retest the turning torque. If less than 8.0 in-lbs of drag, choose a smaller shim and retest the turning torque.
- Remove the transfer gear nut and gear (1).
- Install the puller adapter (9908) (1) onto the low clutch (2).
- Install the overrunning clutch (1) into the low clutch (2).
- Install the needle bearing (1) onto the transfer shaft.
- Install the direct clutch retainer (8) onto the retainer (7).
- Install the return coil spring (5) onto the balance piston (8).
- Install the direct clutch piston (7) into the balance piston (8) using the direct clutch piston guide (9727).
- Install compressor (8250) (2) over the direct clutch balance piston (3) and place onto a arbor press (1).
- Compress the spring in order to install the snap ring (4) for the direct clutch balance piston.
- Install the inner and outer spline frictions (2 and 3).
- Install the number two thrust bearing (9).
- Install the hub (10).
- Install the number one thrust bearing (11).
- Install the selectable reaction plate (12).
- Install the internal snap ring (1).
- Install the direct clutch (1) onto the low clutch (2).
- Install the split bearing (1) using a small pick (2).
- Using a dial indicator and air pressure, measure the direct clutch clearance, the clearance should be between 0.95 to 1.41 mm (0.037 to 0.056 in). Install the desired selectable reaction plate to achieve the correct clearance.
- Install the sun gear (2) onto the shaft.
- Install a new retaining clip (1) onto the transfer/underdrive shaft.
- Inspect the needle bearing (10) in the output hub for any damage.
- Install the thrust washer (9) on the back side of the annulus gear/on the front side of the output hub.
- Install the annulus gear (8).
- Install the thrust washer (7) on the front side of the annulus gear.
- Install the snap ring (6) that holds the annulus gear.
- Install the planetary carrier (5).
- Install the snap ring (4) holding the planetary carrier.
- Install the helical shim (1).
- Install the planetary gear set/output hub (1) onto the direct clutch (2).