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ASSEMBLY, Input Clutch: Assembly: Assembly

WARNING: This page is about a different car, the 2011 RAM Pickup and 2011 RAM Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:

When installing the OD / Reverse piston Belleville spring, orientate it such that it contacts a new surface on the piston.

Fig 1: OD/Reverse Return Spring
GC0092414Courtesy of CHRYSLER LLC
1 - ARBOR PRESS
2 - TOOL 8349 - 1
3 - OD / REVERSE PISTON
  1. Install the Belleville spring and snap ring loosely onto the OD / Reverse piston (3).
  2. Using an Arbor Press (1) and tool (special tool #8349-1, Installer Crank Seal) (2) compress the Belleville spring just enough to install the snap ring.
    Fig 2: Input Clutch Assembly - Part 1
    GC0092413Courtesy of CHRYSLER LLC
    1 - INPUT CLUTCH HUB 11 - UD CLUTCH
    2 - O-RING SEALS 12 - PLATE
    3 - SEAL 13 - CLUTCH RETAINER
    4 - SNAP-RING 14 - SEAL
    5 - SNAP-RING 15 - OD/REV PISTON
    6 - UD BALANCE PISTON 16 - BELLEVILLE SPRING
    7 - SNAP-RING 17 - SNAP-RING
    8 - UD PISTON 18 - SEAL RINGS
    9 - SPRING 19 - INPUT SHAFT
    10 - DISC 20 - LUBRICATION CHECK VALVE AND SNAP-RING
    NOTE:

    Install all new seals and o-rings onto the input shaft and input hub. The o-rings on the input hub are color coded. Be sure to install the correct o-ring in the correct location.

  3. Check the transmission lubrication check valve (20) located in the input shaft using shop air. The valve should only allow air flow in one direction. If the valve allows no air flow, or air flow in both directions, the valve will need to be replaced.
  4. Lubricate all seals with Mopar ® ATF +4, Automatic Transmission Fluid, prior to installation.
  5. Assemble the OD/reverse piston (15) onto the input clutch hub (1). Refer toFig 2.
  6. Assemble the input clutch retainer (13) onto the input clutch hub (1).
  7. Install the input clutch retainer tapered snap-ring (5) with tapered side up onto the input clutch hub (1).
    Fig 3: Installing Piston Guides 8504 Into Input Clutch Retainer
    GC0083002Courtesy of CHRYSLER LLC
    1 - PISTON GUIDES 8504
  8. Install Piston Installer (special tool #8504, Installer) (1) into the input clutch retainer and onto the input clutch hub to guide the inner and outer underdrive piston seals into position. Refer to Fig 3.
  9. Install the underdrive piston into the input clutch retainer and over the input clutch hub.
    Fig 4: Installing Piston Guide 8252 Into Input Clutch Retainer
    GC0083003Courtesy of CHRYSLER LLC
    1 - TOOL 8252
  10. Install the UD balance piston return spring pack into the input clutch retainer.
  11. Install Piston Installer (special tool #8252, Installer) (1) into the input clutch retainer to guide the UD balance piston seal into position inside the underdrive piston. Refer to Fig 4.
    Fig 5: Compressing UD/OD Balance Piston
    GC0083001Courtesy of CHRYSLER LLC
    1 - PRESS
    2 - TOOL 8251
    3 - BALANCE PISTON
    NOTE:

    The UD clutch discs can be identified by their cross-hatched groove pattern (two sets of parallel grooves at 90 degrees to each other). The UD separator plates can be identified by semi-circular cutouts on the edges of the teeth. The reverse clutch and UD clutch use common separator plates.

  12. Install the UD balance piston (3) into the input clutch retainer and the underdrive piston.
  13. Using Spring Compressor (special tool #8251, Compressor, Spring) (2), compress the UD return spring pack and secure the piston in place with the snap-ring. Refer toFig 5.
  14. Install the underdrive clutch pack into the input clutch retainer.
    Fig 6: Input Clutch Assembly - Part 2
    GC0092412Courtesy of CHRYSLER LLC
    1 - THRUST BEARING NUMBER 3 10 - SNAP-RING (SELECT)
    2 - OD HUB/SHAFT 11 - PLATE
    3 - SNAP-RING (WAVE) 12 - DISC
    4 - REV/OD REACTION PLATE 13 - OD CLUTCH
    5 - THRUST BEARING NUMBER 4 14 - SNAP-RING (TAPERED)
    6 - SNAP-RING (FLAT) 15 - UD/OD REACTION PLATE
    7 - REVERSE HUB/SHAFT 16 - SNAP-RING (FLAT)
    8 - REVERSE CLUTCH 17 - UD HUB/SHAFT
    9 - REVERSE REACTION PLATE 18 - THRUST BEARING NUMBER 2
  15. Install the UD reaction plate lower flat snap-ring (16).Refer to Fig 6. The correct snap-ring can be identified by the two tabbed ears.
  16. Install the UD reaction plate (15) into the input clutch retainer. The reaction plate is to be installed with the big step down.
  17. Install the UD reaction plate upper tapered snap-ring (14) with tapered side up.
    Fig 7: Input Clutch Assembly Mounted On Tool 8260
    GC0092415Courtesy of CHRYSLER LLC
    1 - INPUT CLUTCH ASSEMBLY
    2 - TOOL 8260A
  18. Install the input clutch assembly into Input Clutch Pressure Fixture (special tool #8260A, Fixture, Input Clutch) (2). Refer toFig 7.
    Fig 8: Mounting Dial Indicator To Assembly
    GC0083004Courtesy of CHRYSLER LLC
    1 - TOOL C-3339
    2 - UNDERDRIVE CLUTCH PACK
  19. Mount a dial indicator (special tool #C-3339A, Set, Dial Indicator) (1) on the input clutch hub. Push down on the UD clutch discs and zero the indicator against the underdrive clutch discs. Refer to Fig 8. Apply 20 psi of air pressure to the underdrive clutch and record the dial indicator reading. Measure and record UD clutch pack measurement in four (4) places, 90° apart. Take average of four measurements and compare with UD clutch pack clearance specification. The correct clutch clearance is 0.84-1.54 mm (0.033-0.061 in.). The reaction plate is not selective. If the clutch clearance is not within specification, replace the reaction plate along with all the friction and steel discs.
    Fig 9: Input Clutch Assembly - Part 2
    GC0092412Courtesy of CHRYSLER LLC
    1 - THRUST BEARING NUMBER 3 10 - SNAP-RING (SELECT)
    2 - OD HUB/SHAFT 11 - PLATE
    3 - SNAP-RING (WAVE) 12 - DISC
    4 - REV/OD REACTION PLATE 13 - OD CLUTCH
    5 - THRUST BEARING NUMBER 4 14 - SNAP-RING (TAPERED)
    6 - SNAP-RING (FLAT) 15 - UD/OD REACTION PLATE
    7 - REVERSE HUB/SHAFT 16 - SNAP-RING (FLAT)
    8 - REVERSE CLUTCH 17 - UD HUB/SHAFT
    9 - REVERSE REACTION PLATE 18 - THRUST BEARING NUMBER 2
  20. Install the overdrive clutch pack (13) into the input clutch retainer. Refer to Fig 9. The overdrive steel separator plates can be identified by the lack of the half-moon cuts in the locating tabs. The OD clutch discs can be identified by their radial groove pattern. The OD clutch discs can be identified by their radial groove pattern.
  21. Install the overdrive clutch wavy snap-ring (3) with the two tabbed ears into the OD/reverse piston. Refer o Fig 9.
  22. Install the OD/reverse pressure plate (4) into the input clutch retainer. Refer to Fig 9. The pressure plate is non-directional.
  23. Install the OD/reverse reaction plate flat snap-ring (6) into the OD/reverse piston.
    Fig 10: Mounting Dial Indicator To Assembly
    GC0083005Courtesy of CHRYSLER LLC
    1 - TOOL C-3339
    2 - OD/REV REACTION PLATE
  24. Mount a dial indicator (special tool #C-3339A, Set, Dial Indicator) (1) on the input clutch hub and zero the indicator against the OD/reverse pressure plate (2). Refer to Fig 10. Apply 20 psi of air pressure to the overdrive clutch and record the dial indicator reading. Measure and record OD clutch pack measurement in four (4) places, 90° apart. Take average of four measurements and compare with OD clutch pack clearance specification. Verify that the clutch clearance is 1.103-1.856 mm (0.043-0.073 in.). The pressure plate is not selective. If the clutch clearance is not within specification, replace the pressure plate along with all the friction and steel discs.
  25. Install the reverse clutch pack into the input clutch retainer. Refer toFig 6.
  26. Install the reverse reaction plate into the input clutch retainer.
  27. Install the reverse reaction plate selective snap-ring into the input clutch retainer.
    Fig 11: Mounting Dial Indicator To Assembly
    GC0083006Courtesy of CHRYSLER LLC
    1 - TOOL C-3339
    2 - REVERSE CLUTCH PACK
  28. Mount a dial indicator to the assembly, push down on the clutch discs, pull up on the reaction plate to ensure the plate is properly seated and zero the indicator against the reverse clutch discs (2).Refer to Fig 11. Apply 20 psi of air pressure to the reverse clutch and record the dial indicator reading. Measure and record Reverse clutch pack measurement in four (4) places, 90° apart. Take average of four measurements and compare with Reverse clutch pack clearance specification. The correct clutch clearance is 0.81-1.24 mm (0.032-0.049 in.). Adjust as necessary. Install the chosen snap-ring and re-measure to verify selection.
    NOTE:

    The 545RFE uses one of three (3) different selective snap rings. They are identified by the end cuts (either straight [square] cut or "butterfly" [S-curved] cut):

    SELECTABLE END PLAY SNAP RINGS

    • One Square End, One Buttery Fly End = 1.55 mm (0.061 in.)
    • Both Ends Square Cut = 1.85 mm (0.073 in)
    • Both Ends Buttery Fly Cut = 2.2 mm (0.087 in.)
    Fig 12: Input Clutch Assembly - Part 2
    GC0092412Courtesy of CHRYSLER LLC
    1 - THRUST BEARING NUMBER 3 10 - SNAP-RING (SELECT)
    2 - OD HUB/SHAFT 11 - PLATE
    3 - SNAP-RING (WAVE) 12 - DISC
    4 - REV/OD REACTION PLATE 13 - OD CLUTCH
    5 - THRUST BEARING NUMBER 4 14 - SNAP-RING (TAPERED)
    6 - SNAP-RING (FLAT) 15 - UD/OD REACTION PLATE
    7 - REVERSE HUB/SHAFT 16 - SNAP-RING (FLAT)
    8 - REVERSE CLUTCH 17 - UD HUB/SHAFT
    9 - REVERSE REACTION PLATE 18 - THRUST BEARING NUMBER 2
  29. Remove the reverse clutch pack (8) from the input clutch retainer. Refer to Fig 12.
  30. Install the number 2 thrust bearing (18) onto the underdrive hub (17) with outer race against the hub with petroleum jelly.
  31. Install the underdrive hub (17) into the input clutch retainer.
  32. Install the number 3 thrust bearing (1) into the overdrive hub (2) with the outer race against the hub with petroleum jelly. Refer to Fig 12.
  33. Install the overdrive hub (2) into the input clutch retainer.
  34. Install the number 4 thrust bearing (5) into the reverse hub with outer race against the hub with petroleum jelly.
  35. Install the reverse hub (7) into the input clutch retainer.
  36. Install the complete reverse clutch pack (8).
  37. Install the reverse reaction plate (9) and snap-ring (10).
  38. Push up on reaction plate to allow reverse clutch to move freely.
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