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: Install Input Shaft

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   1 - INPUT SHAFT

   2 - ARBOR PRESS RAM

   3 - INPUT SHAFT HUB ASSEMBLY

2. Install input shaft snap ring. See Fig 2.
   Fig 2: Install Input Shaft Snap Ring

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   1 - INPUT SHAFT

   2 - SCREWDRIVER (DO NOT SCRATCH BEARING SURFACE)

   3 - SNAP RING

   4 - O-RINGS

   5 - SEALS

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

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   1 - OD/REVERSE PISTON

   2 - RETURN SPRING

   3 - SNAP RING

   4 - O-RING

   Fig 4: Install 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 - SPECIAL TOOL 6057

   5 - OD/REVERSE PISTON

   6 - RETURN SPRING

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

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   1 - PUSH DOWN TO INSTALL OVERDRIVE/REVERSE PISTON

   2 - INPUT CLUTCHES RETAINER

5. Install the input hub/shaft assy. to the OD/Reverse piston/clutch retainer assy. See Fig 6.
   Fig 6: Install 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 input hub tapered snap ring. See Fig 7. See Fig 8.
   Fig 7: Install 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

   Fig 8: Input Clutch Hub, Retainer, and 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. Install UD clutch piston. See Fig 9.
   Fig 9: Underdrive Clutch Piston

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   1 - PISTON

8. Install UD piston return spring and Tool 5067 as shown in Fig 10.
   Fig 10: Seal Compressor Special Tool 5067

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   1 - PISTON RETURN SPRING

   2 - SPECIAL TOOL 5067

   3 - INPUT SHAFT CLUTCHES RETAINER ASSEMBLY

9. Using Tool 5059A and an arbor press, Install the UD spring retainer and snap ring. See Fig 11. See Fig 12 Compress just enough to install snap ring. See Fig 13.
   CAUTION: Compress return spring just enough to install snap ring.
   Fig 11: UD Return Spring and Retainer

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   1 - UNDERDRIVE SPRING RETAINER

   2 - SNAP RING

   3 - SEAL

   4 - PISTON RETURN SPRING

   Fig 12: Install UD Spring Retainer and Snap Ring

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   1 - ARBOR PRESS RAM

   2 - SNAP RING PLIERS

   3 - SNAP RING

   4 - OD/REVERSE PISTON

   5 - TOOL 5067

   6 - TOOL 5059A

   Fig 13: Underdrive Clutch Piston, Spring and 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

10. Install the UD clutch pack. Leave out upper disc, until snap ring is installed. See Fig 14.
    Fig 14: Install Underdrive Clutch Pack

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    1 - CLUTCH DISC

    2 - CLUTCH PLATE

11. Install the UD clutch flat snap ring. See Fig 15.
    Fig 15: UD Clutch Flat Snap Ring

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    1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING

    2 - SCREWDRIVER

12. Install the last UD clutch disc. See Fig 16.
    Fig 16: Install Last UD Clutch Disc

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    1 - ONE UNDERDRIVE CLUTCH DISC

13. Install the OD/UD clutch reaction plate and snap ring. See Fig 17. See Fig 18. The OD/UD clutches reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up.
    Fig 17: OD/UD Reaction Plate

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

    Fig 18: Tapered Snap Ring

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    1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING

    2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)

    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 19. See Fig 20.
    Fig 19: Seating Tapered Snap Ring

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    1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING

    2 - SCREWDRIVER

    Fig 20: Underdrive Clutch Assembly

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    1 - SNAP RING (TAPERED)

    2 - OD/UD REACTION PLATE

    3 - CLUTCH DISC (3)

    4 - SNAP RING (FLAT)

    5 - CLUTCH PLATE (3)

    6 - INPUT CLUTCH ASSEMBLY

15. Install input clutch assembly to the Input Clutch Pressure Fixture-Tool 8391. See Fig 21.
    Fig 21: Input Clutch Assembly on Pressure Fixture Tool 8391

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    1 - INPUT CLUTCH ASSEMBLY

    2 - INPUT CLUTCH PRESSURE FIXTURE 8391

16. Set up dial indicator on the UD clutch pack as shown in Fig 22.
    Fig 22: Set Up Dial Indicator to Measure UD Clutch Clearance

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    1 - DIAL INDICATOR

    2 - UNDERDRIVE CLUTCH

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 23. When releasing pressure on clutch pack, indicator reading should advance 0.005-0.010.
    Fig 23: Press Down on UD Clutch Pack and Zero Dial Indicator

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    1 - DIAL INDICATOR

    2 - UNDERDRIVE CLUTCH

    CAUTION: Do not apply more than 30 psi (206 kPa) to the underdrive clutch pack.
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:

    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.)

21. Install the OD clutch pack. See Fig 24.
    Fig 24: Install Overdrive Clutch Pack

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    1 - CLUTCH DISC

    2 - CLUTCH PLATE

22. Install OD pressure plate waved snap ring. See Fig 25.
    Fig 25: Install Waved Snap Ring

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    1 - OVERDRIVE PRESSURE PLATE WAVED SNAP RING

    2 - SCREWDRIVER

23. Install the OD/Reverse pressure plate with large step down (towards OD clutch pack). See Fig 26.
    Fig 26: OD/Reverse Reaction Plate

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    1 - OVERDRIVE/REVERSE PRESSURE PLATE

    2 - (STEP SIDE DOWN)

24. Install OD pressure plate flat snap ring. See Fig 27. See Fig 28.
    Fig 27: Install Flat Snap Ring

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    1 - ARBOR PRESS RAM

    2 - TOOL 5059A

    3 - FLAT SNAP RING

    Fig 28: Overdrive Clutch Assembly

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    1 - SNAP RING

    2 - OD/REVERSE PRESSURE PLATE

    3 - SNAP RING (WAVE)

    4 - CLUTCH DISC (3)

    5 - CLUTCH STEEL (2)

    6 - INPUT CLUTCH ASSEMBLY

25. Measure OD clutch pack clearance. Set up dial indicator on top of the OD/Reverse pressure plate as shown in Fig 29.
    Fig 29: Measure OD Clutch Pack Clearance

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    1 - DIAL INDICATOR

    2 - OD/REVERSE REACTION PLATE

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 frictions/one steel). See Fig 30.
    Fig 30: Install Reverse Clutch Pack

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    1 - REVERSE CLUTCH PLATE

    2 - REVERSE CLUTCH DISCS

29. Install reverse clutch reaction plate with the flat side down towards reverse clutch. See Fig 31.
    Fig 31: Install Reaction Plate

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    1 - REVERSE CLUTCH REACTION PLATE (FLAT SIDE DOWN)

30. Tap reaction plate down to allow installation of the reverse clutch snap ring. Install reverse clutch snap ring. See Fig 32. See Fig 33.
    Fig 32: Install Reverse Clutch Snap Ring

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    1 - REVERSE CLUTCH SNAP RING (SELECT)

    2 - SCREWDRIVER

    3 - REVERSE CLUTCH REACTION PLATE

    Fig 33: 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

31. Pry up reverse reaction plate to seat against snap ring. See Fig 34.
    Fig 34: Pry Up Reaction Plate

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    1 - SCREWDRIVER

    2 - SNAP RING

    3 - SCREWDRIVER

    4 - MUST RAISE REVERSE REACTION PLATE TO RAISE SNAP RING

32. Set up a dial indicator on the reverse clutch pack as shown in Fig 35.
    Fig 35: Measure Reverse Clutch Pack Clearance

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    1 - DIAL INDICATOR

    2 - REVERSE CLUTCH

33. Using moderate pressure, press down and hold (near indicator) reverse clutch disc with screwdriver or suitable tool and zero dial indicator. See Fig 36. When releasing pressure, indicator should advance 0.005-0.010. as clutch pack relaxes.
    Fig 36: Press Down on Reverse Clutch and Zero Indicator

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    1 - DIAL INDICATOR

    2 - REVERSE CLUTCH

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:

    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.)

36. To complete the assembly, reverse clutch and overdrive clutch must be removed.
37. Install the #2 needle bearing. See Fig 37.
    Fig 37: Install No. 2 Needle Bearing

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

    2 - TABS UP

38. Install the underdrive shaft assembly. See Fig 38.
    Fig 38: Install Underdrive Shaft Assembly

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    1 - UNDERDRIVE SHAFT ASSEMBLY

    2 - #2 NEEDLE BEARING

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

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    1 - #3 THRUST WASHER (NOTE 5 TABS)

    2 - UNDERDRIVE SHAFT ASSEMBLY

40. Install the #3 thrust plate to the bottom of the overdrive shaft assembly. Retain with petrolatum or transmission assembly gel. See Fig 40.
    Fig 40: Install 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)

41. Install the overdrive shaft assembly. See Fig 41. See Fig 42.
    Fig 41: Install Overdrive Shaft Assembly

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    1 - OVERDRIVE SHAFT ASSEMBLY

    2 - #3 THRUST PLATE

    3 - #3 THRUST WASHER

    Fig 42: 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

42. Reinstall overdrive and reverse clutch as shown. Rechecking these clutch clearances is not necessary.