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Input Clutch Assembly: Disassembly

Fig 1: Tapping Reaction Plate
GC0000768Courtesy of DAIMLERCHRYSLER CORP.
1 - #4 THRUST PLATE (SELECT)
2 - TAP DOWN REVERSE CLUTCH REACTION PLATE TO REMOVE OR INSTALL SNAP RING
3 - INPUT SHAFT CLUTCHES RETAINER ASSEMBLY
4 - REVERSE CLUTCH REACTION PLATE
  1. Mount input clutch assembly (3) to Input Clutch Pressure Fixture Tool 8391. See Fig 1.
  2. Tap down reverse clutch reaction plate (4) to release pressure from snap ring (2).
    Fig 2: Removing Reverse Clutch Snap Ring
    GC0000769Courtesy of DAIMLERCHRYSLER CORP.
    1 - REACTION PLATE
    2 - SCREWDRIVER
    3 - REVERSE CLUTCH SNAP RING (SELECT)
  3. Remove reverse clutch snap ring (3). See Fig 2.
    Fig 3: Pry Reverse Clutch Reaction Plate
    GC0000770Courtesy of DAIMLERCHRYSLER CORP.
    1 - REVERSE CLUTCH REACTION PLATE
    2 - SCREWDRIVER
    3 - SCREWDRIVER
  4. Pry up and remove reverse clutch reaction plate (1). See Fig 3.
    Fig 4: Reverse Clutch Assembly
    GC0000797Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP RING
    2 - REACTION PLATE
    3 - CLUTCH DISC (2)
    4 - CLUTCH PLATE (1)
    5 - INPUT CLUTCH ASSEMBLY
  5. Remove reverse clutch pack (3,4). See Fig 4. Tag components for assembly identification. 
    Fig 5: Overdrive Clutch Assembly
    GC0000798Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP RING
    2 - OD/REVERSE PRESSURE PLATE
    3 - SNAP RING (WAVE)
    4 - CLUTCH DISC (4)
    5 - CLUTCH STEEL (3)
    6 - INPUT CLUTCH ASSEMBLY
  6. Remove the OD/Reverse pressure plate snap ring (1). See Fig 5.
  7. Remove OD/Reverse pressure plate (2).
  8. Remove OD/Reverse pressure plate wave snap ring (3).
  9. Remove OD clutch pack (4,5). Tag components for assembly identification. 
    Fig 6: Overdrive/Underdrive Shafts
    GC0000800Courtesy of DAIMLERCHRYSLER CORP.
    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
  10. Remove and inspect OD (1) and UD Shafts (4), as well as #3 thrust washer and plate (2, 3), and #2 needle bearing (5). See Fig 6.
    Fig 7: Underdrive Clutch Assembly
    GC0000799Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP RING (TAPERED)
    2 - OD/UD REACTION PLATE
    3 - CLUTCH DISC
    4 - SNAP RING (FLAT)
    5 - CLUTCH PLATE
    6 - INPUT CLUTCH ASSEMBLY
  11. Remove the OD/UD reaction plate tapered snap ring (1), clutch plate (5), and first clutch disc (3). See Fig 7.
  12. Remove the UD clutch flat snap ring (4) and rest of the input clutch assembly (6). Tag clutch pack for assembly identification. 
    Fig 8: Removing/Installing UD Spring Retainer Snap Ring
    GC0000786Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP RING PLIERS
    2 - ARBOR PRESS RAM
    3 - SNAP RING
    4 - COMPRESSOR 5059A
    CAUTION: Compress return spring just enough to remove or install snap ring.
  13. Using compressor 5059A (4) and an arbor press (2), compress UD clutch piston/spring enough to remove snap ring (3). See Fig 8.
    Fig 9: Underdrive Clutch Piston, Spring & Retainer
    GC0000801Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP RING
    2 - SPRING RETAINER
    3 - SPRING
    4 - UD CLUTCH PISTON
    5 - SEAL, OUTER
    6 - SEAL, INNER
    7 - INPUT CLUTCH ASSEMBLY
  14. Refer to the exploded view as necessary when performing the following steps
  15. Remove spring retainer (2), spring (3), and UD clutch piston (4). See Fig 9.
    Fig 10: View Of Input Hub Tapered Snap Ring
    GC0000789Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT SHAFT
    2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN CAVITY)
    3 - SNAP RING PLIERS
  16. Remove input hub tapered snap ring (2). See Fig 10.
    Fig 11: Tapping Out Input Hub
    GC0000790Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT SHAFT AND HUB ASSEMBLY
    2 - SOFT FACED HAMMER
  17. Tap on input hub with soft faced hammer (2) and separate input hub from OD/Reverse piston and clutch retainer. See Fig 11.
    Fig 12: Pulling Retainer from Piston
    GC0000792Courtesy of DAIMLERCHRYSLER CORP.
    1 - OVERDRIVE/REVERSE PISTON
    2 - INPUT CLUTCHES RETAINER
  18. Separate clutch retainer (2) from OD/Reverse piston (1). See Fig 12.
    Fig 13: Removing/Installing OD/Reverse Piston Snap Ring
    GC0000793Courtesy of DAIMLERCHRYSLER CORP.
    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
  19. Using Disk 6057 (4) and an arbor press (1), compress return OD/Reverse piston return spring just enough to remove snap ring (3). See Fig 13.
    Fig 14: Removing Input Shaft Snap Ring
    GC0000795Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT SHAFT
    2 - SHARP-POINTED TOOL
    3 - SNAP RING
    4 - O-RINGS
    5 - SEALS
  20. Remove input shaft to input clutch hub snap ring (3). See Fig 14.
    Fig 15: Remove Input Shaft
    GC0000796Courtesy of DAIMLERCHRYSLER CORP.
    1 - ARBOR PRESS RAM
    2 - SOCKET
    3 - SEAL
    4 - O-RINGS
    5 - INPUT SHAFT
    6 - SEAL
    7 - INPUT SHAFT HUB ASSEMBLY
  21. Using a suitably sized socket (2) and an arbor press (1), remove input shaft (5) from input shaft hub (7). See Fig 15.
    Fig 16: Input Clutch Hub, Retainer & OD/Reverse Piston
    GC0000802Courtesy of DAIMLERCHRYSLER CORP.
    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
  22. Refer to the exploded view as necessary when performing the above steps
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