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Home >> GMC >> 2006 >> Sierra 1500 HD, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 920 (Automatic Transmission - ALLISON - Removal & Installation, Service, Overhaul, Troubleshooting & Diagnosis) >> Off-Vehicle Repair Instructions >> 1-2-3-4-5-6 Clutch Piston Housing Assemble

1-2-3-4-5-6 Clutch Piston Housing Assemble

WARNING: This page is about a different car, the 2007 GMC Sierra and 2007 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.

Tools Required

    Fig 1: Piston Seal Rings
    GM1580989Courtesy of GENERAL MOTORS CORP.
  1. Install the piston seal rings (1, 2) onto the 4-5-6 clutch piston (3).
  2. Lubricate the 4-5-6 clutch piston ID and OD seal rings (1, 2) with J 36850  . See Special Tools .
    3. Fig 2: View Of 1-2-3-4, 4-5-6 Clutch Housing Inner Hub O-Ring
    GM1217054Courtesy of GENERAL MOTORS CORP.
  3. Position the 1-2-3-4, 4-5-6 clutch housing (2) on the work table so that the rear of the housing is facing up.
  4. Install the O-ring (1) into the bottom groove on the inner hub of the 1-2-3-4, 4-5-6 clutch housing (2).
    5. Fig 3: 4-5-6 Clutch Piston
    GM1660855Courtesy of GENERAL MOTORS CORP.
  5. Position the 4-5-6 clutch piston (1) on the work table so that the rear of the piston is facing up.
  6. Install the 4-5-6 clutch piston (1) into the 1-2-3-4, 4-5-6 clutch housing (2).
  7. Make sure the 4-5-6 clutch piston (1) is seated on the 1-2-3-4, 4-5-6 clutch housing (2).
    8. Fig 4: 1-2-3-4 Clutch Piston Housing Seal Ring
    GM1580991Courtesy of GENERAL MOTORS CORP.
  8. Install the seal ring (1) onto the 1-2-3-4 clutch piston housing (2).
  9. Lubricate the 1-2-3-4 clutch piston housing seal (1) with J 36850  . See Special Tools .
    10. Fig 5: View Of 1-2-3-4 Clutch Piston Housing & 1-2-3-4, 4-5-6 Clutch Housing
    GM1217056Courtesy of GENERAL MOTORS CORP.
  10. Align the 4-5-6 clutch piston return spring assembly (2) so that the notches of the spring assemblies are facing and aligned with the tangs of the 4-5-6 clutch piston (4).
  11. Install the 4-5-6 clutch piston return spring assembly (2) into the 4-5-6 clutch piston (4).
  12. Align the 1-2-3-4 clutch piston housing (1) so that the rear of the housing is facing up.
  13. Install the 1-2-3-4 clutch piston housing (1) into the 4-5-6 clutch piston (4).
    14. Fig 6: 1-2-3-4-, 4-5-6 Clutch Housing & J 24204-2
    GM1580985Courtesy of GENERAL MOTORS CORP.
  14. Position the 1-2-3-4, 4-5-6 clutch housing (8) on the base of J 24204-2  (10) so that the rear of the housing is facing up. See Special Tools .
  15. Install J-47339-2  (7) onto the shaft of J 24204-2  with the bowl down. See Special Tools .
  16. Install the retaining ring (6) onto the surface of J-47339-2  (7). See Special Tools .
  17. Install the spring (5) of J-47339-2  onto the shaft of J 24204-2  . See Special Tools .
  18. Install J-47339-1  (4) onto the shaft of J 24204-2  . See Special Tools .
  19. Install the J 24204-2  ball bearing (3) and washer (2) onto the shaft of J 24204-2  . See Special Tools .
  20. Install the J 24204-2  wing nut (1) onto the shaft of J 24204-2  . See Special Tools .
  21. Compress the 4-5-6 clutch piston return spring assembly until the retaining ring groove on the inner hub of the 1-2-3-4, 4-5-6 clutch housing (8) is visible.
  22. Install the retaining ring (6) into the 1-2-3-4, 4-5-6 clutch housing inner hub.
  23. Make sure the retaining ring (6) is seated all around the clutch housing (8).
  24. Remove all J tools.
    25. Fig 7: Locating Clutch Piston Seal Rings
    GM1217058Courtesy of GENERAL MOTORS CORP.
  25. Install the 1-2-3-4 clutch piston ID seal ring (1) and the 1-2-3-4 clutch piston OD seal ring (2) onto the 1-2-3-4 clutch piston (3).
  26. Lubricate the seal rings with J 36850  . See Special Tools .
    27. Fig 8: 1-2-3-4 Clutch Piston Housing Components
    GM1580984Courtesy of GENERAL MOTORS CORP.
  27. Position the 1-2-3-4, 4-5-6 clutch housing (4) on the work table so that the rear of the housing is facing up.
  28. Align the 1-2-3-4 clutch piston (3) so that the spring indents are facing up.
  29. Install the 1-2-3-4 clutch piston (3) into the 1-2-3-4 clutch piston housing (4).
  30. Make sure the 1-2-3-4 clutch piston (3) is seated in the 1-2-3-4 clutch piston housing (4).
  31. Align the 1-2-3-4 clutch piston return spring assembly (2) so that the springs are facing and aligned with the spring pockets of 1-2-3-4 clutch piston (3).
  32. Install the 1-2-3-4 clutch piston return spring assembly (2) into the 1-2-3-4 clutch piston (3).
  33. Lubricate the 1-2-3-4 clutch balance piston ID and OD seal area with J 36850  . See Special Tools .
  34. Align the 1-2-3-4 clutch balance piston (1) and position so that the rubber seal is facing down.
    35. Fig 9: 1-2-3-4-, 4-5-6 Clutch Housing & J 24204-2
    GM1580982Courtesy of GENERAL MOTORS CORP.
  35. Position the 1-2-3-4, 4-5-6 clutch housing (6) on the base of J 24204-2  (7) so that the rear of the housing is facing up. See Special Tools .
  36. Install J-47339-1  (4) onto the shaft of J 24204-2  (7). See Special Tools .
  37. Center J-47339-1  (4) on the 1-2-3-4 clutch balance piston. See Special Tools .
  38. Install the J 24204-2  ball bearing (3) and washer (2) onto the shaft of J 24204-2  . See Special Tools .
  39. Install the J 24204-2  wing nut (1) on the shaft of J 24204-2  . See Special Tools .
  40. Compress the 1-2-3-4 clutch piston return spring assembly until the retaining ring groove on the 1-2-3-4 clutch housing is visible.
  41. Install the retaining ring (5) into the 1-2-3-4 clutch housing.
  42. Remove all of the J tools.
    43. Fig 10: Locating Turbine Shaft & Overlap Seal Rings
    GM1217064Courtesy of GENERAL MOTORS CORP.
  43. Install 2 overlap seal rings (4) onto the turbine shaft (3).
  44. Position the turbine shaft (3) on the work table so that the rear of the shaft is facing up.
  45. Align the 1-2-3-4, 4-5-6 clutch housing (2) with the rear of the turbine shaft (3) so that the rear of the clutch housing is facing up.
  46. Install the 1-2-3-4, 4-5-6 clutch housing (2) onto the rear of turbine shaft (3).
  47. Install the retaining ring (1) onto the turbine shaft (3).
  48. Make sure the retaining ring (1) is seated completely around the turbine shaft (3).
    49. Fig 11: Identifying Stacking Sequence Of Clutch Plates
    GM1217065Courtesy of GENERAL MOTORS CORP.
  49. Starting with a 1-2-3-4 clutch steel plate, alternately install 6 1-2-3-4 clutch steel plates (2) and 6 1-2-3-4 clutch fiber plates (1) onto the turbine shaft (3).
    50. Fig 12: Installing J44525 Onto Turbine Shaft
    GM1564018Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Special tools J 44525-4 selector tool (4) and J 44525-5 pressure plate (3) are silver plated for easy identification. Do not use the pressure plate and selector tool from the J 44525  set if they are not matched in color. See Special Tools .
  50. Align J 44525-5 pressure plate (3) with the turbine shaft so that the countersunk holes of J 44525-5 pressure plate (3) are facing up.
  51. Install J 44525-5 pressure plate (3) onto the turbine shaft.
  52. Align J 44525-1 compressor (2) with the turbine shaft so that the inner ridge of J 44525-1 compressor (2) is facing down.
  53. Slide the inner ridge of J 44525-1 compressor (2) into the turbine shaft retaining ring groove.
  54. Align the holes in J 44525-1 compressor (2) with the countersunk holes of J 44525-5 pressure plate (3).
    55. NOTE: Refer to Fastener Notice .
  55. Hand install 2 bolts (1) of J 44525  into the holes of J 44525-1 compressor (2). See Special Tools .

    Tighten:  Tighten the bolts to 1.8 N.m (16 lb in).

    56. Fig 13: Using J 44525 To Select Correct 1-2-3-4 Clutch Backing Plate
    GM1660858Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The shift quality of the transmission depends heavily upon selecting the correct 1-2-3-4 clutch backing plate.
  56. Perform the following procedure for each tab of J 44525-4 selector tool (1):
    1. Place the flat surface, tabbed end of J 44525-4 selector tool (1) onto the top surface of J 44525-5 pressure plate (3).
      IMPORTANT: At most, 2 of the different tabs will fit into the retaining ring groove.
    2. Try to slide the tabbed end of J 44525-4 selector tool (1) into the retaining ring groove on the turbine shaft.
    3. If a tab fits into the retaining ring groove, record the 4-digit ID number located on the tab of J 44525-4 selector tool (1). Refer to Selective Components Specifications to determine the correct backing plate.
  57. Select a 1-2-3-4 clutch backing plate as follows:
    • If no tab of J 44525-4 selector tool (1) fits into the retaining ring groove, select the 1-2-3-4 clutch backing plate with ID No. 2420.
    • If one or more tabs of J 44525-4 selector tool (1) fit into the retaining ring groove, select the 1-2-3-4 clutch backing plate with an ID No. corresponding to the highest number recorded in the previous step.
  58. Remove J 44525  from the turbine shaft. See Special Tools .
    59. Fig 14: View Of 1-2-3-4 Clutch Backing Plate
    GM1217070Courtesy of GENERAL MOTORS CORP.
  59. Align the selected 1-2-3-4 clutch backing plate (3) so that the beveled edge of the backing plate is facing up.
  60. Install the 1-2-3-4 clutch backing plate (3) onto the turbine shaft (4).
  61. Install the retaining ring (2) onto the turbine shaft (4).
  62. Lift the 1-2-3-4 clutch backing plate (3) and install the spiral retaining ring (1) into the 1-2-3-4 clutch backing plate (3).
    63. Fig 15: Locating 1-2-3-4 Clutch Thrust Bearing Assembly & Turbine Shaft
    GM1217071Courtesy of GENERAL MOTORS CORP.
    NOTE: Installing the thrust bearing assembly onto the rear of the turbine shaft in the wrong direction may cause permanent damage to the transmission. The blue stripe must be visible.
  63. Align thrust bearing assembly (2) so that the blue stripe on the thrust bearing assembly is facing away from turbine shaft (3).
  64. Install the thrust bearing assembly (2) into the turbine shaft (3).
  65. Make sure the blue stripe on the thrust bearing assembly is visible.
  66. Center the 1-2-3-4 clutch plates (4).
  67. Install the 1-2-3-4 clutch drive hub (1) over the 1-2-3-4 clutch plates (4).
  68. Make sure the 1-2-3-4 clutch drive hub (1) has seated on the thrust bearing assembly (2).
    69. Fig 16: Identifying Correct Installation Position Of 1-2-3-4 Clutch Thrust Bearing Assembly
    GM1409527Courtesy of GENERAL MOTORS CORP.
    NOTE: Installing the thrust bearing assembly onto the rear of the 1-2-3-4 drive hub in the wrong direction may cause permanent damage to the transmission. The blue stripe must be visible.
  69. Align the thrust bearing assembly (2) so that the blue stripe on the thrust bearing assembly is facing away from the 1-2-3-4 clutch drive hub (3).
  70. Install the thrust bearing assembly (2) onto the rear of the 1-2-3-4 clutch drive hub (3).
  71. Make sure the blue stripe on the thrust bearing assembly is visible.
  72. Align the 4-5-6 clutch drive hub (1) so that the smaller end is facing up.
  73. Install the 4-5-6 clutch drive hub (1).
    74. Fig 17: Illustrating Stacking Sequence Of 4-5-6 Clutch Steel & Fiber Plates
    GM1217074Courtesy of GENERAL MOTORS CORP.
  74. Starting with a 4-5-6 clutch steel plate, alternately install seven 4-5-6 clutch steel plates (2) and six 4-5-6 clutch fiber plates (1) into the 1-2-3-4, 4-5-6 clutch housing.
    75. Fig 18: Identifying Bronze Thrust Washer With Holes
    GM1217075Courtesy of GENERAL MOTORS CORP.
  75. Align the tangs of the bronze thrust washer (1) with the holes in the 4-5-6 clutch drive hub (2).
  76. Install the bronze thrust washer (1) onto the 4-5-6 clutch drive hub (2).
    77. Fig 19: View Of 1-2-3-4, 4-5-6 Clutch Housing Components
    GM1217076Courtesy of GENERAL MOTORS CORP.
  77. Align the input sun gear (3) so that the gear teeth of the sun gear face the concave face of the input sun gear flange (2).
  78. Install the input sun gear (3) into the input sun gear flange (2).
  79. Make sure the splines are engaged.
  80. Hold the sun gear and align the double wide splines of the input sun gear flange (2) with the double wide spaces on the 1-2-3-4, 4-5-6 clutch housing (4).
  81. Install the input sun gear (3) with the input sun gear flange (2) into the 1-2-3-4, 4-5-6 clutch housing (4).
  82. Install the input sun gear external retaining ring (1) into the 1-2-3-4, 4-5-6 clutch housing (4).
  83. Make sure the retaining ring is seated all the way around the 1-2-3-4, 4-5-6 clutch housing.
  84. Remove tools J 24204-2  and J 43777  . See Special Tools .
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