Input Clutch Assembly: Assembly

Use petrolatum on all seals to ease assembly of components.

1. Using an arbor press, install input shaft to input shaft hub. See Fig 1.
   Fig 1: Installing Input Shaft

   Courtesy of DAIMLERCHRYSLER CORP.
2. Install input shaft snap ring. See Fig 2.
   Fig 2: Installing Input Shaft Snap Ring

   Courtesy of DAIMLERCHRYSLER CORP.
3. Using an arbor press and Tool 6057, Install OD/Reverse piston return spring and snap ring. See Fig 3 and Fig 4 .
   Fig 3: Installing Return Spring & Snap Ring

   Courtesy of DAIMLERCHRYSLER CORP.
   Fig 4: Installing Snap Ring

   Courtesy of DAIMLERCHRYSLER CORP.
4. Install the OD/Reverse piston assembly to the input clutch retainer as shown in Fig 5.
   Fig 5: Installing OD/Reverse Piston

   Courtesy of DAIMLERCHRYSLER CORP.
   NOTE: The OD/UD Reaction Plate, Snap Rings, and Input Clutch Retainer are not interchangeable with previous year 41TE components. The snap rings are thicker and the position of the ring lands have changed.
5. Install the input hub/shaft assembly. to the OD/Reverse piston/clutch retainer ashy. See Fig 6.
   Fig 6: Installing Input Shaft Hub Assembly

   Courtesy of DAIMLERCHRYSLER CORP.
6. Install input hub tapered snap ring. See Fig 7. Make sure snap ring is fully seated. 
   Fig 7: Installing Input Hub Tapered Snap Ring

   Courtesy of DAIMLERCHRYSLER CORP.
7. Install UD clutch piston. See Fig 8.
   Fig 8: Installing Underdrive Clutch Piston

   Courtesy of DAIMLERCHRYSLER CORP.
8. Install UD piston return spring and Tool 5067 as shown in Fig 9.
   Fig 9: Installing Seal Compressor Special Tool 5067

   Courtesy of DAIMLERCHRYSLER CORP.
9. Using Tool 5059A and an arbor press, install the UD spring retainer and snap ring. See Fig 10 and Fig 11 . Compress just enough to install snap ring.
   CAUTION: Compress return spring just enough to install snap ring.
   Fig 10: Installing UD Return Spring & Retainer

   Courtesy of DAIMLERCHRYSLER CORP.
   Fig 11: Install UD Spring Retainer & Snap Ring

   Courtesy of DAIMLERCHRYSLER CORP.
10. Install the UD clutch pack (four fibers/four steels). See Fig 12. Leave the top disc out until after the snap ring is installed.
    Fig 12: Installing Underdrive Clutch Pack

    Courtesy of DAIMLERCHRYSLER CORP.
11. Install the UD clutch flat snap ring. See Fig 13.
    Fig 13: Installing UD Clutch Flat Snap Ring

    Courtesy of DAIMLERCHRYSLER CORP.
12. Install the last UD clutch disc. See Fig 14.
    Fig 14: Installing Last UD Clutch Disc

    Courtesy of DAIMLERCHRYSLER CORP.
13. Install the OD/UD clutch reaction plate and snap ring. See Fig 15 and Fig 16 . The OD/UD clutches reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up.
    Fig 15: Installing OD/UD Reaction Plate

    Courtesy of DAIMLERCHRYSLER CORP.
    Fig 16: Installing Tapered Snap Ring

    Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: Snap ring ends must be located within one finger of the input clutch hub. Be sure that snap ring is fully seated, by pushing with screwdriver, into snap ring groove all the way around.
14. Seat tapered snap ring to ensure proper installation. See Fig 17.
    Fig 17: Seating Tapered Snap Ring

    Courtesy of DAIMLERCHRYSLER CORP.
15. Install input clutch assembly to the Input Clutch Pressure Fixture-Tool 8391. See Fig 18.
    Fig 18: Installing Input Clutch Assembly On Pressure Fixture Tool 8391

    Courtesy of DAIMLERCHRYSLER CORP.
16. Set up dial indicator on the UD clutch pack as shown in Fig 19.
    Fig 19: Setting Up Dial Indicator To Measure UD Clutch Clearance

    Courtesy of DAIMLERCHRYSLER CORP.
17. Using moderate pressure, press down and hold (near indicator) the UD clutch pack with screwdriver or suitable tool and zero dial indicator. See Fig 20. When releasing pressure on clutch pack, indicator reading should advance 0.005-0.010.
    CAUTION: Do not  apply more than 30 psi (206 kPa) to the underdrive clutch pack.
    Fig 20: Pressing Down On UD Clutch Pack & Zero Dial Indicator

    Courtesy of DAIMLERCHRYSLER CORP.
18. Apply 30 psi (206 kPa) to the underdrive hose on Tool 8391 and measure UD clutch clearance. Measure and record UD clutch pack measurement in four (4) places, 90° apart.
19. Take average of four measurements and compare with UD clutch pack clearance specification. Underdrive clutch pack clearance must be 0.94-1.50 mm (0.037-0.059 in.). 
20. If necessary, select the proper reaction plate to achieve specifications:
21. Install the OD clutch pack (four fibers/three steels). See Fig 21.
    Fig 21: Installing OD Clutch Pack

    Courtesy of DAIMLERCHRYSLER CORP.
22. Install OD reaction plate waved snap ring. See Fig 22.
    Fig 22: Installing Waves Snap Ring

    Courtesy of DAIMLERCHRYSLER CORP.
23. Install the OD/Reverse reaction plate with large step down (towards OD clutch pack). See Fig 23.
    Fig 23: Installing OD/Reverse Reaction Plate

    Courtesy of DAIMLERCHRYSLER CORP.
24. Install OD reaction plate flat snap ring. See Fig 24.
    Fig 24: Installing Flat Snap Ring

    Courtesy of DAIMLERCHRYSLER CORP.
25. Measure OD clutch pack clearance. Set up dial indicator on top of the OD/Reverse reaction plate as shown in Fig 25.
    Fig 25: Measuring OD Clutch Pack Clearance

    Courtesy of DAIMLERCHRYSLER CORP.
26. Zero dial indicator and apply 30 psi (206 kPa) air pressure to the overdrive clutch hose on Tool 8391. Measure and record OD clutch pack measurement in four (4) places, 90° apart.
27. Take average of four measurements and compare with OD clutch pack clearance specification. The overdrive (OD) clutch pack clearance is 1.07-3.25 mm (0.042-0.128 in.). 

    If not within specifications, the clutch is not assembled properly. There is no adjustment for the OD clutch clearance.

28. Install reverse clutch pack (two fibers/one steel). See Fig 26.
    Fig 26: Installing Reverse Clutch Pack

    Courtesy of DAIMLERCHRYSLER CORP.
29. Install reverse clutch reaction plate with the flat side down towards reverse clutch. See Fig 27.
    Fig 27: Installing Reaction Plate

    Courtesy of DAIMLERCHRYSLER CORP.
30. Tap reaction plate down to allow installation of the reverse clutch snap ring. Install reverse clutch snap ring. See Fig 28.
    Fig 28: Installing Reverse Clutch Snap Ring

    Courtesy of DAIMLERCHRYSLER CORP.
31. Pry up reverse reaction plate to seat against snap ring. See Fig 29.
    Fig 29: Prying Up Reaction Plate

    Courtesy of DAIMLERCHRYSLER CORP.
32. Set up a dial indicator on the reverse clutch pack as shown in Fig 30.
33. Using moderate pressure, press down and hold (near indicator) reverse clutch disc with screwdriver or suitable tool and zero dial indicator. See Fig 31. When releasing pressure, indicator should advance 0.005-0.010. as clutch pack relaxes.
    Fig 30: Measuring Reverse Clutch Pack Clearance

    Courtesy of DAIMLERCHRYSLER CORP.
    Fig 31: Pressing Down On Reverse Clutch & Zero Indicator

    Courtesy of DAIMLERCHRYSLER CORP.
34. Apply 30 psi (206 kPa) air pressure to the reverse clutch hose on Tool 8391. Measure and record reverse clutch pack measurement in four (4) places, 90° apart.
35. Take average of four measurements and compare with reverse clutch pack clearance specification. The reverse clutch pack clearance is 0.89-1.37 mm (0.035-0.054 in.).  Select the proper reverse clutch snap ring to achieve specifications:
36. To complete the assembly, reverse clutch and overdrive clutch must be removed.
37. Install the #2 needle bearing. See Fig 32.
    Fig 32: Installing No. 2 Needle Bearing

    Courtesy of DAIMLERCHRYSLER CORP.
38. Install the underdrive shaft assembly. See Fig 33.
    Fig 33: Installing Underdrive Shaft Assembly

    Courtesy of DAIMLERCHRYSLER CORP.
39. Install the #3 thrust washer to the underdrive shaft assembly. Be sure five tabs are seated properly. See Fig 34.
    Fig 34: Installing No. 3 Thrust Washer

    Courtesy of DAIMLERCHRYSLER CORP.
40. Install the #3 thrust plate to the bottom of the overdrive shaft assembly. Retain with petrolatum or transmission assembly gel. See Fig 35.
    Fig 35: Installing No. 3 Thrust Plate

    Courtesy of DAIMLERCHRYSLER CORP.
41. Install the overdrive shaft assembly. See Fig 36.
    Fig 36: Installing Overdrive Shaft Assembly

    Courtesy of DAIMLERCHRYSLER CORP.
42. Reinstall overdrive and reverse clutch as shown in Fig 37. Rechecking these clutch clearances is not necessary. 
    Fig 37: Installing Input Clutch Assembly

    Courtesy of DAIMLERCHRYSLER CORP.