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Input Clutch Assembly: Disassembly

WARNING: This page is about a different car, the 2004 Dodge Dakota. 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 ( Fig 1).
    Fig 1: Tapping Reaction Plate
    G03489235Courtesy of DAIMLERCHRYSLER CORP.
  3. Remove reverse clutch snap ring ( Fig 2).
    Fig 2: Removing Reverse Clutch Snap Ring
    G03489236Courtesy of DAIMLERCHRYSLER CORP.
  4. Pry up and remove reverse clutch reaction plate ( Fig 3) ( Fig 4).
    Fig 3: Prying Reverse Clutch Reaction Plate
    G03489237Courtesy of DAIMLERCHRYSLER CORP.
    Fig 4: Removing Reverse Clutch Reaction Plate
    G03489238Courtesy of DAIMLERCHRYSLER CORP.
  5. Remove the reverse clutch pack (two fibers/one steel) ( Fig 5).
    NOTE: Tag reverse clutch pack for reassembly identification.
    Fig 5: Removing Reverse Clutch Pack
    G03489239Courtesy of DAIMLERCHRYSLER CORP.
  6. Remove the OD/Reverse reaction plate snap ring ( Fig 6).
    Fig 6: Removing OD/Reverse Pressure Plate Snap Ring
    G03489240Courtesy of DAIMLERCHRYSLER CORP.
  7. Remove OD/Reverse pressure plate ( Fig 7).
    Fig 7: Removing OD/Reverse Reaction Plate
    G03489241Courtesy of DAIMLERCHRYSLER CORP.
  8. Remove OD/Reverse reaction plate wave snap ring ( Fig 8).
    Fig 8: Removing Waved Snap Ring
    G03489242Courtesy of DAIMLERCHRYSLER CORP.
  9. Remove OD shaft/hub and OD clutch pack ( Fig 9), ( Fig 10).
    NOTE: Tag overdrive clutch pack for reassembly identification.
    Fig 9: Removing OD Clutch Pack
    G03489243Courtesy of DAIMLERCHRYSLER CORP.
    Fig 10: Removing Overdrive Clutch Pack
    G03489244Courtesy of DAIMLERCHRYSLER CORP.
  10. Remove and inspect #3 & #4 thrust washers ( Fig 11).
    Fig 11: Removing Thrust Washers
    G03489245Courtesy of DAIMLERCHRYSLER CORP.
  11. Remove the underdrive shaft assembly ( Fig 12).
    Fig 12: Removing Underdrive Shaft Assembly
    G03489246Courtesy of DAIMLERCHRYSLER CORP.
  12. Remove the #2 needle bearing ( Fig 13).
    Fig 13: Removing Needle Bearing
    G03489247Courtesy of DAIMLERCHRYSLER CORP.
  13. Remove the OD/UD reaction plate tapered snap ring ( Fig 14).
    Fig 14: Removing Tapered Snap Ring
    G03489248Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: The OD/UD clutch reaction plate has a step on both sides. The OD/UD clutches reaction plate goes tapered step side up.
  14. Remove the OD/UD reaction plate ( Fig 15).
    Fig 15: Removing OD/UD Reaction Plate
    G03489249Courtesy of DAIMLERCHRYSLER CORP.
  15. Remove the first UD clutch disc ( Fig 16).
    Fig 16: Removing UD Clutch Disc
    G03489250Courtesy of DAIMLERCHRYSLER CORP.
  16. Remove the UD clutch flat snap ring ( Fig 17).
    NOTE: Tag underdrive clutch pack for reassembly identification.
    Fig 17: Removing UD Clutch Flat Snap Ring
    G03489251Courtesy of DAIMLERCHRYSLER CORP.
  17. Remove the UD clutch pack ( Fig 18).
    Fig 18: Removing Underdrive Clutch Pack
    G03489252Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: Compress return spring just enough to remove or install snap ring.
  18. Using Tool 5059A and an arbor press, compress UD clutch piston enough to remove snap ring ( Fig 19), ( Fig 20).
    Fig 19: Removing Spring Retainer Snap Ring
    G03489253Courtesy of DAIMLERCHRYSLER CORP.
  19. Remove spring retainer ( Fig 20).
    Fig 20: Removing Spring Retainer
    G03489254Courtesy of DAIMLERCHRYSLER CORP.
  20. Remove UD clutch piston ( Fig 21).
    Fig 21: Removing Underdrive Clutch Piston
    G03489255Courtesy of DAIMLERCHRYSLER CORP.
  21. Remove input hub tapered snap ring ( Fig 22).
    Fig 22: Removing Input Hub Tapered Snap Ring
    G03489256Courtesy of DAIMLERCHRYSLER CORP.
  22. Tap on input hub with soft faced hammer and separate input hub from OD/Reverse piston and clutch retainer ( Fig 23), ( Fig 24).
    Fig 23: Taping On Input Hub
    G03489257Courtesy of DAIMLERCHRYSLER CORP.
    Fig 24: Removing Input Hub
    G03489258Courtesy of DAIMLERCHRYSLER CORP.
  23. Separate clutch retainer from OD/Reverse piston ( Fig 25).
    Fig 25: Pulling Retainer From Piston
    G03489259Courtesy of DAIMLERCHRYSLER CORP.
  24. Using Tool 6057 and an arbor press, compress return OD/Reverse piston return spring just enough to remove snap ring ( Fig 26), ( Fig 27).
    Fig 26: Removing Snap Ring
    G03489260Courtesy of DAIMLERCHRYSLER CORP.
    Fig 27: Removing Return Spring And Snap Ring
    G03489261Courtesy of DAIMLERCHRYSLER CORP.
  25. Remove input shaft to input clutch hub snap ring ( Fig 28).
    Fig 28: Removing Input Shaft Snap Ring
    G03489262Courtesy of DAIMLERCHRYSLER CORP.
  26. Using a suitably sized socket and an arbor press, remove input shaft from input shaft hub ( Fig 29).
    Fig 29: Removing Input Shaft
    G03489263Courtesy of DAIMLERCHRYSLER CORP.
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