Input Clutch Assembly: Assembly

Fig 1: Installing Input Shaft

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Use petrolatum on all seals to ease assembly of components.

1. Using an arbor press (2), install input shaft (1) to input shaft hub (3). See Fig 1.
   Fig 2: View Of Input Shaft Snap Ring And O-Rings

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   1 - INPUT SHAFT

   2 - SCREWDRIVER (DO NOT SCRATCH BEARING SURFACE)

   3 - SNAP RING

   4 - O-RINGS

   5 - SEALS

2. Install input shaft snap ring (3). See Fig 2.
   Fig 3: Return Spring & Snap Ring

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   1 - OD/REVERSE PISTON

   2 - RETURN SPRING

   3 - SNAP RING

   4 - O-RING

3. Place OD/Reverse piston (1). See Fig 3return spring (2) and snap ring (3) into position.
   Fig 4: Removing/Installing OD/Reverse Piston Snap Ring

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   1 - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST ENOUGH TO REMOVE OR INSTALL SNAP RING)

   2 - SCREWDRIVER

   3 - SNAP RING

   4 - Disk 6057

   5 - OD/REVERSE PISTON

   6 - RETURN SPRING

4. Using an arbor press (1). See Fig 4and Disk 6057 (4), install OD/Reverse piston (5) return spring (6) and snap ring (3).
   Fig 5: Installing OD/Reverse Piston

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   1 - PUSH DOWN TO INSTALL OVERDRIVE/REVERSE PISTON

   2 - INPUT CLUTCHES RETAINER

5. Install the OD/Reverse piston assembly (1) to the input clutch retainer (2). See Fig 5.
   Fig 6: Installing Input Shaft Hub Assembly

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   1 - PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY (ROTATE TO ALIGN SPLINES)

   2 - OD/REV. PISTON

6. Install the input hub/shaft assy. (rotate to align splines) (1) to the OD/Reverse piston/clutch retainer assy. (2). See Fig 6.
   Fig 7: Input Clutch Hub, Retainer & OD/Reverse Piston

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   1 - SNAP RING (INPUT SHAFT)

   2 - SNAP RING

   3 - CLUTCH RETAINER

   4 - SEAL, OUTER

   5 - SEAL, INNER

   6 - OD/REVERSE PISTON

   7 - SEAL, INPUT SHAFT

   8 - SHAFT, INPUT

   9 - HUB

   10 - SEAL

   11 - SNAP RING

   12 - BELLEVILLE SPRING

7. Refer to the exploded view as necessary when performing the following steps. See Fig 7.
   Fig 8: Identifying Input Hub Tapered Snap Ring

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   1 - INPUT SHAFT

   2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN CAVITY)

   3 - SNAP RING PLIERS

8. Install input hub tapered snap ring (tapered side up with tabs in cavity) (2). See Fig 8.
   Fig 9: Underdrive Clutch Piston

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   1 - PISTON

9. Install UD clutch piston (1). See Fig 9.
   Fig 10: Seal Compressor Special Tool 5067

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   1 - PISTON RETURN SPRING

   2 - INSTALLER 5067

   3 - INPUT SHAFT CLUTCHES RETAINER ASSEMBLY

10. Install UD piston return spring (1) and Installer 5067 (2). See Fig 10.
    Fig 11: Underdrive Clutch Piston, Spring & Retainer

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    1 - SNAP RING

    2 - SPRING RETAINER

    3 - SPRING

    4 - UD CLUTCH PISTON

    5 - SEAL, OUTER

    6 - SEAL, INNER

    7 - INPUT CLUTCH ASSEMBLY

11. Refer to the exploded view as necessary when performing the following steps. See Fig 11.
    Fig 12: UD Return Spring & Retainer

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    1 - UNDERDRIVE SPRING RETAINER

    2 - SNAP RING

    3 - SEAL

    4 - PISTON RETURN SPRING

12. Place the UD spring retainer (1) and snap ring (2) into position. See Fig 12.
    Fig 13: Installing UD Spring Retainer & Snap Ring

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    1 - ARBOR PRESS RAM

    2 - SNAP RING PLIERS

    3 - SNAP RING

    4 - OD/REVERSE PISTON

    5 - INSTALLER 5067

    6 - COMPRESSOR 5059A

13. Using Compressor 5059A (6) and an arbor press (1), Install the UD spring retainer and snap ring (3) Compress just enough to install snap ring (3). See Fig 13.
    CAUTION: Compress return spring just enough to install snap ring.
    Fig 14: Identifying Underdrive Clutch Pack Components

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    1 - CLUTCH PLATE

    2 - ONE UD CLUTCH DISC

    3 - CLUTCH DISC

14. Install the UD clutch pack (1,3). See Fig 14. Leave out upper disc (2), until snap ring is installed.
    Fig 15: UD Clutch Flat Snap Ring

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    1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING

    2 - SCREWDRIVER

15. Install the UD clutch flat snap ring (1). See Fig 15.
    Fig 16: Removing/Installing Last UD Clutch Disc

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    1 - ONE UNDERDRIVE CLUTCH DISC

16. Install the last UD clutch disc (1). See Fig 16.
    Fig 17: OD/UD Reaction Plate

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    1 - OD/UD CLUTCH REACTION PLATE (TAPERED STEP SIDE UP)

17. Place the OD/UD clutch reaction plate (1). See Fig 17and snap ring into position. The OD/UD clutches reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up.
    Fig 18: Removing Tapered Snap Ring

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    1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING

    2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)

18. Install the snap ring (1) using a screwdriver (2). See Fig 18.
    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.
    Fig 19: Underdrive Clutch Assembly

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    1 - SNAP RING (TAPERED)

    2 - OD/UD REACTION PLATE

    3 - CLUTCH DISC

    4 - SNAP RING (FLAT)

    5 - CLUTCH PLATE

    6 - INPUT CLUTCH ASSEMBLY

19. Refer to the exploded view as necessary when performing the following steps. See Fig 19.
    Fig 20: Seating Tapered Snap Ring

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    1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING

    2 - SCREWDRIVER

20. Seat tapered snap ring (1) to ensure proper installation. See Fig 20.
    Fig 21: Input Clutch Assembly on Pressure Fixture Tool

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    1 - INPUT CLUTCH ASSEMBLY

    2 - INPUT CLUTCH PRESSURE FIXTURE 8391

21. Install input clutch assembly (1) to the Input Clutch Pressure Fixture 8391 (2). See Fig 21.
    Fig 22: Setting Up Dial Indicator To Measure UD Clutch Clearance

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    1 - DIAL INDICATOR

    2 - UNDERDRIVE CLUTCH

22. Set up dial indicator (1) on the UD clutch pack (2). See Fig 22.
    Fig 23: Pressing Down On UD Clutch Pack & Zeroing Dial Indicator

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    1 - DIAL INDICATOR

    2 - UNDERDRIVE CLUTCH

23. Using moderate pressure, press down and hold (near indicator) the UD clutch pack (2) with screwdriver or suitable tool and zero dial indicator. See Fig 23. 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.
24. Apply 30 psi (206 kPa) to the underdrive hose on Input Clutch Pressure Fixture 8391 and measure UD clutch clearance. Measure and record UD clutch pack measurement in four (4) places, 90° apart.
25. Take average of four measurements and compare with UD clutch pack (2) clearance specification. Underdrive clutch pack clearance must be 0.94-1.50 mm (0.037-0.059 in.). 
26. If necessary, select the proper reaction plate to achieve specifications:

    UNDERDRIVE REACTION PLATE THICKNESS
    4659939AB	5.837-5.937 mm (0.230-0.234 in.)
    4659940AB	6.147-6.248 mm (0.242-0.246 in.)
    4659941AB	6.457-6.557 mm (0.254-0.258 in.)

    Fig 24: View Of OD Clutch Pack

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    1 - OVERDRIVE CLUTCH PACK

27. Install the OD clutch pack (four frictions/three steels) (1). See Fig 24.
    Fig 25: Identifying Waved Snap Ring

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    1 - OVERDRIVE PRESSURE PLATE WAVED SNAP RING

    2 - SCREWDRIVER

28. Install OD pressure plate waved snap ring (1). See Fig 25.
    Fig 26: OD/Reverse Pressure Plate

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    1 - OVERDRIVE/REVERSE PRESSURE PLATE

    2 - (STEP SIDE DOWN)

29. Install the OD/Reverse pressure plate (1) with large step down (towards OD clutch pack) (2). See Fig 26.
    Fig 27: Overdrive Clutch Assembly

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    1 - SNAP RING

    2 - OD/REVERSE PRESSURE PLATE

    3 - SNAP RING (WAVE)

    4 - CLUTCH DISC (4)

    5 - CLUTCH STEEL (3)

    6 - INPUT CLUTCH ASSEMBLY

30. Refer to the exploded view as necessary when performing the following steps. See Fig 27.
    Fig 28: Installing Flat Snap Ring

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    1 - ARBOR PRESS RAM

    2 - COMPRESSOR 5059A

    3 - FLAT SNAP RING

31. Install OD pressure plate flat snap ring (3). See Fig 28.
    Fig 29: Measuring OD Clutch Pack Clearance

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    1 - DIAL INDICATOR

    2 - OD/REVERSE REACTION PLATE

32. Measure OD clutch pack clearance. Set up dial indicator (1) on top of the OD/Reverse pressure plate. See Fig 29.
33. 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.
34. 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.

    Fig 30: Identifying Reverse Clutch Pack Components

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    1 - REVERSE CLUTCH PLATE

    2 - REVERSE CLUTCH DISCS

35. Install reverse clutch pack (two frictions/one steel) (1,2). See Fig 30.
    Fig 31: Identifying Reaction Plate

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    1 - REVERSE CLUTCH REACTION PLATE (FLAT SIDE DOWN)

36. Install reverse clutch reaction plate with the flat side down towards reverse clutch. See Fig 31.
    Fig 32: Reverse Clutch Assembly

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    1 - SNAP RING

    2 - REACTION PLATE

    3 - CLUTCH DISC (2)

    4 - CLUTCH PLATE (1)

    5 - INPUT CLUTCH ASSEMBLY

37. Refer to the exploded view as necessary when performing the following steps. See Fig 32.
    Fig 33: Installing Reverse Clutch Snap Ring

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    1 - REVERSE CLUTCH SNAP RING (SELECT)

    2 - SCREWDRIVER

    3 - REVERSE CLUTCH REACTION PLATE

38. Tap reaction plate (3) down to allow installation of the reverse clutch snap ring (1) Install reverse clutch snap ring (1). See Fig 33.
    Fig 34: Prying Up Reaction Plate to Seat Against Snap Ring

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    1 - SCREWDRIVER

    2 - SNAP RING

    3 - SCREWDRIVER

    4 - MUST RAISE REVERSE REACTION PLATE TO RAISE SNAP RING

39. Pry up reverse reaction plate (4) to seat against snap ring (2). See Fig 34.
    Fig 35: Measuring Reverse Clutch Pack Clearance

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    1 - DIAL INDICATOR

    2 - REVERSE CLUTCH

40. Set up a dial indicator (1) on the reverse clutch pack (2). See Fig 35.
    Fig 36: Pressing Down On Reverse Clutch & Zeroing Indicator

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    1 - DIAL INDICATOR

    2 - REVERSE CLUTCH

41. Using moderate pressure, press down and hold (near indicator) reverse clutch disc (2) with screwdriver or suitable tool and zero dial indicator (1). When releasing pressure, indicator should advance 0.005-0.010. as clutch pack relaxes. See Fig 36.
42. Apply 30 psi (206 kPa) air pressure to the reverse clutch hose on Input Clutch Pressure Fixture 8391. Measure and record reverse clutch pack measurement in four (4) places, 90° apart.
43. 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:

    REVERSE CLUTCH SNAP RING THICKNESS
    4377195	1.53-1.58 mm (0.060-0.062 in.)
    4412871	1.77-1.83 mm (0.070-0.072 in.)
    4412872	2.02-2.07 mm (0.080-0.082 in.)
    4412873	2.27-2.32 mm (0.090-0.091 in.)

    Fig 37: Identifying No. 2 Needle Bearing

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    1 - #2 NEEDLE BEARING (NOTE 3 SMALL TABS)

    2 - TABS UP

44. To complete the assembly, reverse clutch and overdrive clutch must be removed.
45. Install the #2 needle bearing (note 3 small tabs up) (1). See Fig 37.
    Fig 38: Identifying Underdrive Shaft Assembly

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    1 - UNDERDRIVE SHAFT ASSEMBLY

    2 - #2 NEEDLE BEARING

46. Install the underdrive shaft assembly (1). See Fig 38.
    Fig 39: Identifying No. 3 Thrust Washer

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    1 - #3 THRUST WASHER (NOTE 5 TABS)

    2 - UNDERDRIVE SHAFT ASSEMBLY

47. Install the #3 thrust washer (1) to the underdrive shaft assembly (2). Be sure five tabs are seated properly. See Fig 39.
    Fig 40: Installing No. 3 Thrust Plate

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    1 - OVERDRIVE SHAFT ASSEMBLY

    2 - DABS OF PETROLATUM (FOR RETENTION)

    3 - #3 THRUST PLATE (NOTE 3 TABS)

48. Install the #3 thrust plate (3) (note 3 tabs) to the bottom of the overdrive shaft assembly (1). Retain with petrolatum or transmission assembly gel (2). See Fig 40.
    Fig 41: Overdrive/Underdrive Shafts

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    1 - OVERDRIVE SHAFT

    2 - #3 THRUST PLATE (3 TABS)

    3 - #3 THRUST WASHER (5 TABS)

    4 - UNDERDRIVE SHAFT

    5 - #2 NEEDLE BEARING (3 TABS)

    6 - INPUT CLUTCH ASSEMBLY

49. Refer to the exploded view as necessary when performing the following steps. See Fig 41.
    Fig 42: Identifying Overdrive Shaft Assembly

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    1 - OVERDRIVE SHAFT ASSEMBLY

    2 - #3 THRUST PLATE

    3 - #3 THRUST WASHER

50. Install the overdrive shaft assembly (1). See Fig 42.
51. Reinstall overdrive and reverse clutch as shown in illustration. Rechecking these clutch clearances is not necessary.