Clutch, 3: Assembly: Assembly

WARNING: This page is about a different car, the 2016 RAM 3500 HD. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Apply trans jell or petroleum jelly to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR® ASRC ATF. Soak all friction discs in MOPAR® ASRC ATF for at least two hours before assembly of clutch packs.

Fig 1: K3 Clutch Exploded View

Courtesy of CHRYSLER GROUP, LLC

1 - SNAP RING

2 - REACTION PLATE

3 - DISC

4 - PLATE

5 - SNAP RING

6 - BALANCE PISTON

7 - O-RING

8 - PISTON RETURN SPRING

9 - PISTON

10 - D-RING

11 - D-RING

12 - CLUTCH RETAINER

Fig 2: K3 Piston

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Lubricate K3 clutch piston seals with MOPAR® ASRC ATF and install the piston into the K3 clutch retainer.

Fig 3: K3 Return Spring
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Install the K3 clutch piston return spring into the K3 clutch retainer.

Fig 4: K3 Balance Piston
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Lubricate the seals on the K3 clutch balance piston with MOPAR ® ASRC ATF and install it into the K3 clutch retainer.

Fig 5: K3 Piston Compress
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1 - ARBOR PRESS

2 - COMPRESSOR 5059
Using an arbor press (1) and Compressor tool (special tool #5059-A, Compressor, Spring) (2), compress the K3 clutch piston assembly.

Fig 6: K3 Piston Snap Ring
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Install the K3 piston snap ring using snap ring pliers.

Fig 7: K3 Clutch Pack
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1 - Item_1

2 - Item _2
Install the K3 clutch pack.

Fig 8: K3 Clutch Pack Snap Ring
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1 - Item_1

2 - Item _2

Install the K3 clutch snap ring.

CLUTCH CLEARANCE AND PISTON TRAVEL COMBINATIONS

	Measurement Item	Condition	Suspected Cause	Action
	Clutch Clearance	Normal	Discs/Plates are worn thin and warped, snap ring and groove height, piston wear.	Replace the discs and plates and recheck clearances. If not OK- Check the piston, snap ring and snap ring groove
	Piston Travel	High
LOW PROBABILITY	Clutch Clearance	Normal	Piston travel issue (interference, obstruction from broken part) or Discs/Plates are too thick (above specs.) and snap ring grove at wrong height (high).	Replace the discs and plates and recheck clearances. If not OK- Check the piston, snap ring and snap ring groove
	Piston Travel	Low
LOW PROBABILITY	Clutch Clearance	High	Low possibility, piston height, snap-ring groove, snap-ring thickness, disk and plates thickness and flatness.	Replace the discs and plates and recheck clearances. If not OK- Check the piston, snap ring and snap ring groove.
	Piston Travel	Normal
	Clutch Clearance	High	Discs/Plates are worn (thin) or snap ring thickness groove height, piston height.	Replace the discs and plates and recheck clearances. If not OK- Check the piston, snap ring and snap ring groove.
	Piston Travel	High
LOW PROBABILITY	Clutch Clearance	High	Piston travel issue (interference, obstruction from broken part combined with improper piston height, snap ring groove wear or height, or snap ring thickness) or piston does not fully return.	Replace the discs and plates and recheck clearances. If not OK- Check the piston, snap ring and snap ring groove.
	Piston Travel	Low
	Clutch Clearance	Low	Discs/Plates are not flat or combination of high piston height and low snap ring groove height.	Replace the discs and plates and recheck clearances. If not OK- Check the piston, snap ring and snap ring groove.
	Piston Travel	Normal
	Clutch Clearance	Low	Discs/Plates are worn (thin) and warped.	Replace the discs and plates and recheck clearances. If not OK- Check the piston, snap ring and snap ring groove
	Piston Travel	High
	Clutch Clearance	Low	Discs/Plates are too thick/extra discs or snap ring height too low or piston too tall.	Replace the discs and plates and recheck clearances. If not OK- Check the piston, snap ring and snap ring groove
	Piston Travel	Low

Fig 9: K3 Piston Stroke

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1 - AIR APPLY

2 -9524 90° DIAL INDICATOR

3 - K3 CLUTCH

Fig 10: K3 Piston Stroke Dial Indicator Tip

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1 - SP-1917 90° DIAL INDICATOR TIP

2 - PISTON VOIDS

3 - 9524 90° DIAL INDICATOR

NOTE:

If the K3 piston assembly stroke is not within tolerance check the K3 piston seals and the hydraulic fluid circuit path.

Install the K3 clutch assembly into the transmission case.

Install the 90° Dial Indicator (special tool #9524, Indicator, Dial) (3) with the SP1917 90° dial indicator tip (1) and mounts from the Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator), being certain the dial indicator tip is positioned into a piston void (2) so that the tip contacts the piston, apply 400 - 500 kPa (58 - 72 psi) of air to check the K3 clutch piston stroke clearance.

Refer to DIAGNOSIS AND TESTING .

The K3 clutch piston stroke clearance is 1.55 - 1.85 mm (0.061 - 0.073 in.).

Fig 11: Checking K3 Clutch Pack Clearance

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1 - AIR APPLY

2 - 90° DIAL INDICATOR 9524

3 - K3 CLUTCH PACK

Install the K3 clutch pack assembly into the transmission case.
NOTE:
The selectable clutch pack reaction plates are identified by an alpha numeric numeral stamped into the face of the plate.
Install the 90° Dial Indicator (special tool #9524, Indicator, Dial) and mounts from Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator) and apply 400 - 500 kPa (58 - 72 psi) of air to check the K3 clutch pack clearance.
Refer to DIAGNOSIS AND TESTING .

The K3 clutch pack clearance is 1.25 - 1.50 mm (0.049 - 0.059 in.). If the clearance is not within tolerance, choose the correct selectable reaction plate.

P = 6.30 mm (0.248 in.)
Q = 6.45 mm (0.254 in.)
R = 6.60 mm (0.260 in.)
S = 6.75 mm (0.266 in.)
T = 6.90 mm (0.272 in.)