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Input Clutch Assembly: Disassembly

WARNING: This page is about a different car, the 2005 Dodge Stratus and 2005 Chrysler Sebring. However, it is still accessible from the selected car via links, so may be relevant.
  1. Mount input clutch assembly to Input Clutch Pressure Fixture (Tool 8391).
  2. Tap down reverse clutch reaction plate to release pressure from snap ring. See Fig 1.
    Fig 1: Tapping Reaction Plate
    GC0020607Courtesy 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
  3. Remove reverse clutch snap ring. See Fig 2.
    Fig 2: Reverse Clutch Snap Ring
    GC0020608Courtesy of DAIMLERCHRYSLER CORP.
    1 - REACTION PLATE
    2 - SCREWDRIVER
    3 - REVERSE CLUTCH SNAP RING (SELECT)
  4. Pry up and remove reverse clutch reaction plate. See Fig 3.
    Fig 3: Pry Reverse Clutch Reaction Plate
    GC0020609Courtesy of DAIMLERCHRYSLER CORP.
    1 - REVERSE CLUTCH REACTION PLATE
    2 - SCREWDRIVER
    3 - SCREWDRIVER
  5. Remove reverse clutch pack. See Fig 4. Tag components for assembly identification. 
    Fig 4: Reverse Clutch Assembly
    GC0020636Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP RING
    2 - REACTION PLATE
    3 - CLUTCH DISC (2)
    4 - CLUTCH PLATE (1)
    5 - INPUT CLUTCH ASSEMBLY
  6. Remove the OD/Reverse pressure plate snap ring. See Fig 5.
  7. Remove OD/Reverse pressure plate. See Fig 5.
  8. Remove OD/Reverse pressure plate wave snap ring. See Fig 5.
  9. Remove OD clutch pack. See Fig 5. Tag components for assembly identification. 
    Fig 5: Overdrive Clutch Assembly
    GC0020637Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP RING
    2 - OD/REVERSE PRESSURE PLATE
    3 - SNAP RING (WAVE)
    4 - CLUTCH DISC (3)
    5 - CLUTCH STEEL (2)
    6 - INPUT CLUTCH ASSEMBLY
  10. Remove and inspect OD and UD Shafts, as well as #3 thrust washer and plate, and #2 needle bearing. See Fig 6.
    Fig 6: Overdrive/Underdrive Shafts
    GC0020639Courtesy 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
  11. Remove the OD/UD reaction plate tapered snap ring, reaction plate, and first friction disc. See Fig 7.
  12. Remove the UD clutch flat snap ring and rest of UD clutch pack. See Fig 7. Tag clutch pack for assembly identification. 
    Fig 7: Underdrive Clutch Assembly
    GC0020638Courtesy of DAIMLERCHRYSLER CORP.
    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
    CAUTION: Compress return spring just enough to remove or install snap ring.
  13. Using Tool 5059A and an arbor press, compress UD clutch piston/spring enough to remove snap ring. See Fig 8. See Fig 9.
    Fig 8: UD Spring Retainer Snap Ring
    GC0020625Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP RING PLIERS
    2 - ARBOR PRESS RAM
    3 - SNAP RING
    4 - SPECIAL TOOL 5059A
  14. Remove spring retainer, spring, and piston. See Fig 9.
    Fig 9: Underdrive Clutch Piston, Spring and Retainer
    GC0020640Courtesy 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
  15. Remove input hub tapered snap ring. See Fig 10. See Fig 16.
    Fig 10: Input Hub Tapered Snap Ring
    GC0020628Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT SHAFT
    2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN CAVITY)
    3 - SNAP RING PLIERS
  16. Tap on input hub with soft faced hammer and separate input hub from OD/Reverse piston and clutch retainer. See Fig 11.
    Fig 11: Tap on Input Hub
    GC0020629Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT SHAFT AND HUB ASSEMBLY
    2 - PLASTIC HAMMER
  17. Separate clutch retainer from OD/Reverse piston. See Fig 12.
    Fig 12: Pull Retainer from Piston
    GC0020631Courtesy of DAIMLERCHRYSLER CORP.
    1 - OVERDRIVE/REVERSE PISTON
    2 - INPUT CLUTCHES RETAINER
  18. Using Tool 6057 and an arbor press, compress return OD/Reverse piston return spring just enough to remove snap ring. See Fig 13.
    Fig 13: Install Snap Ring
    GC0020632Courtesy of DAIMLERCHRYSLER CORP.
    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
  19. Remove input shaft to input clutch hub snap ring. See Fig 14. See Fig 16.
    Fig 14: Remove Input Shaft Snap Ring
    GC0020634Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT SHAFT
    2 - SHARP-POINTED TOOL
    3 - SNAP RING
    4 - O-RINGS
    5 - SEALS
  20. Using a suitably sized socket and an arbor press, remove input shaft from input shaft hub. See Fig 15.
Fig 15: Remove Input Shaft
GC0020635Courtesy of DAIMLERCHRYSLER CORP.
1 - ARBOR PRESS RAM
2 - SOCKET
3 - SEAL
4 - O-RINGS
5 - INPUT SHAFT
6 - SEAL
7 - INPUT SHAFT HUB ASSEMBLY
Fig 16: Input Clutch Hub, Retainer, and OD/Reverse Piston
GC0020641Courtesy 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
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