GEARTRAIN And Direct Clutch

WARNING: This page is about a different car, the 2003 Dodge Dakota. However, it is still accessible from the selected car via links, so may be relevant.

Soak direct clutch and overdrive clutch discs in Mopar® ATF +4, Automatic Transmission fluid. Allow discs to soak for 10-20 minutes.
Install new pilot bushing and clutch hub bushing in output shaft if necessary (Fig 1). Lubricate bushings with petroleum jelly, or transmission fluid.

Fig 1: Installing Output Shaft Pilot Bushing
Courtesy of DAIMLERCHRYSLER CORP.
Install annulus gear on output shaft, if removed. Then install annulus gear retaining snap-ring (Fig 2).

Fig 2: Installing Annulus Gear
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Align and install clutch drum on annulus gear (Fig 3). Be sure drum is engaged in annulus gear lugs.

Fig 3: Installing Clutch Drum And Outer Retaining Ring
Courtesy of DAIMLERCHRYSLER CORP.
Install clutch drum outer retaining ring (Fig 3).
Slide clutch drum forward and install inner retaining ring (Fig 4).
Install rear bearing and snap ring on output shaft (Fig 5). Be sure locating ring groove in bearing is toward rear.

Fig 4: Installing Clutch Drum Inner Retaining Ring
Courtesy of DAIMLERCHRYSLER CORP.

Fig 5: Installing Rear Bearing And Snap-Ring On Output Shaft
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Install overrunning clutch on hub (Fig 6). Note that clutch only fits one way. Shoulder on clutch should seat in small recess at edge of hub.
Install thrust bearing on overrunning clutch hub. Use generous amount of petroleum jelly to hold bearing in place for installation. Bearing fits one way only. Be sure bearing is seated squarely against hub. Reinstall bearing if it does not seat squarely.

Fig 6: Assembling Overrunning Clutch And Hub
Courtesy of DAIMLERCHRYSLER CORP.
Install overrunning clutch in output shaft (Fig 7). Insert snap ring pliers in hub splines. Expand pliers to grip hub. Then install assembly with counterclockwise, twisting motion.

Fig 7: Installing Overrunning Clutch
Courtesy of DAIMLERCHRYSLER CORP.
Install planetary gear in annulus gear (Fig 8). Be sure planetary pinions are fully seated in annulus gear before proceeding.

Fig 8: Installing Planetary Gear
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Coat planetary thrust bearing and bearing contact surface of spring plate with generous amount of petroleum jelly. This will help hold bearing in place during installation.
Install planetary thrust bearing on sun gear (Fig 9). Slide bearing onto gear and seat it against spring plate as shown. Bearing fits one way only. If it does not seat squarely against spring plate, remove and reposition bearing.

Fig 9: Installing Planetary Thrust Bearing
Courtesy of DAIMLERCHRYSLER CORP.
Install assembled sun gear, spring plate and thrust bearing (Fig 10). Be sure sun gear and thrust bearing are fully seated before proceeding.

Fig 10: Installing Sun Gear
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Mount assembled output shaft, annulus gear, and clutch drum in shop press. Direct clutch spring, hub and clutch pack are easier to install with assembly mounted in press.
Align splines in hubs of planetary gear and overrunning clutch with Alignment tool 6227-2 (Fig 11). Insert tool through sun gear and into splines of both hubs. Be sure alignment tool is fully seated before proceeding.

Fig 11: Aligning Splines In Hubs Of Planetary Gear And Overrunning Clutch
Courtesy of DAIMLERCHRYSLER CORP.
Install direct clutch spring (Fig 12). Be sure spring is properly seated on spring plate.

Fig 12: Installing Direct Clutch Spring
Courtesy of DAIMLERCHRYSLER CORP.

NOTE: The direct clutch in a 46RE transmission uses 8 clutch discs.
Assemble and install direct clutch pack on hub as follows:
1. Assemble clutch pack components (Fig 14).
  
  Fig 13: Identifying 46RE Direct Clutch Pack Components
  Courtesy of DAIMLERCHRYSLER CORP.
2. Install direct clutch reaction plate on clutch hub first. Note that one side of reaction plate is counterbored. Be sure this side faces rearward. Splines at rear of hub are raised slightly. Counter-bore in plate fits over raised splines. Plate should be flush with this end of hub (Fig 13).
  
  Fig 14: Installing Direct Clutch Reaction Plate On Clutch Hub
  Courtesy of DAIMLERCHRYSLER CORP.
3. Install first clutch disc followed by a steel plate until all discs and plates have been installed.
4. Install pressure plate. This is last clutch pack item to be installed. Be sure plate is installed with shoulder side facing upward (Fig 15).
  
  Fig 15: Installing Pressure Plate
  Courtesy of DAIMLERCHRYSLER CORP.
Install clutch hub and clutch pack on direct clutch spring (Fig 16). Be sure hub is started on sun gear splines before proceeding.
WARNING: THE NEXT STEP IN GEARTRAIN ASSEMBLY INVOLVES COMPRESSING THE DIRECT CLUTCH HUB AND SPRING. IT IS EXTREMELY IMPORTANT THAT PROPER EQUIPMENT BE USED TO COMPRESS THE SPRING AS SPRING FORCE IS APPROXIMATELY 830 POUNDS. USE COMPRESSOR TOOL C-6227-1 AND A HYDRAULIC-TYPE SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 6 INCHES. THE PRESS MUST ALSO HAVE A BED THAT CAN BE ADJUSTED UP OR DOWN AS REQUIRED. RELEASE CLUTCH SPRING TENSION SLOWLY AND COMPLETELY TO AVOID PERSONAL INJURY.

Fig 16: Installing Direct Clutch Pack And Clutch Hub
Courtesy of DAIMLERCHRYSLER CORP.
Position Compressor Tool 6227-1 on clutch hub.
Compress clutch hub and spring just enough to place tension on hub and hold it in place.
Slowly compress clutch hub and spring. Compress spring and hub only enough to expose ring grooves for clutch pack snap ring and clutch hub retaining ring.
Realign clutch pack on hub and seat clutch discs and plates in clutch drum.
Install direct clutch pack snap ring (Fig 17). Be very sure snap ring is fully seated in clutch drum ring groove.

Fig 17: Installing Direct Clutch Pack Snap-Ring
Courtesy of DAIMLERCHRYSLER CORP.
Install clutch hub retaining ring (Fig 18). Be very sure retaining ring is fully seated in sun gear ring groove.

Fig 18: Installing Clutch Hub Retaining Ring
Courtesy of DAIMLERCHRYSLER CORP.
Slowly release press ram, remove compressor tools and remove geartrain assembly.