Intermediate and Overdrive and Reverse Clutch Hub Assemble

Special Tools

• J 23327:  Clutch Spring Compressor
• J 44764:  Clutch Spring Compressor
• J 45126:  Snap Ring Pliers
• J 45135:  Seal Protector

For equivalent regional tools, refer to Special Tools .

Fig 1: Identifying Overdrive & Intermediate Clutch Housing Inspection Areas
Courtesy of GENERAL MOTORS CORP.
1. Inspect the housing for the following:
   • Plugged feed passages
   • Worn or damaged splines
   • Damaged or worn springs
   • Damaged or worn pistons
   • Worn or damaged clutch plates
Fig 2: Identifying Intermediate Piston & Intermediate Clutch Housing
Courtesy of GENERAL MOTORS CORP.
2. Install the intermediate piston (495) into the intermediate clutch housing (496).
Fig 3: Identifying Overdrive Clutch Housing & Components
Courtesy of GENERAL MOTORS CORP.
3. Install the intermediate clutch spring (494).
4. Install the intermediate housing (496).
Fig 4: Identifying Intermediate Clutch Housing Retainer Ring
Courtesy of GENERAL MOTORS CORP.
5. Use J 44764:  spring compressor and J 23327:  spring compressor to compress the housing.
6. Install the intermediate clutch housing retainer ring (497).
7. Remove J 44764:  spring compressor and J 23327:  spring compressor.
Fig 5: Identifying Intermediate Clutch Plates
Courtesy of GENERAL MOTORS CORP.
8. Install the intermediate apply plate (492).
9. Install the intermediate clutch plates. Starting with the intermediate clutch plates (491) with external splines. Alternating with the intermediate clutch plates (490) internal splines. Refer to Clutch Plate Selection Specifications .
10. Install the backing plate (489).
11. Install the intermediate backing plate retainer ring (488).
Fig 6: Measuring Distance Between Intermediate Clutch Backing Plate & Bottom Of Gage Bar
Courtesy of GENERAL MOTORS CORP.
12. Measure the distance between the intermediate clutch backing plate and the bottom of the gage bar. Measure three times in different locations on the backing plate. Record this as H1.
13. Apply 65 PSI (448.17 kPa) of air pressure to the specified port. Measure the distance between the intermediate clutch backing plate and the bottom of the gage bar. Measure three times in different locations on the backing plate. Record this as H2.
14. Subtract H2 from H1 this is the clutch pack travel. Refer to Clutch Piston Travel Specifications .
Fig 7: Installing Overdrive Piston
Courtesy of GENERAL MOTORS CORP.
15. Use J 45135:  seal protector (2) and J 44764:  spring compressor (1) to install the overdrive piston (487).
Fig 8: Locating Overdrive Piston Spring & Retainer Ring
Courtesy of GENERAL MOTORS CORP.
16. Install the overdrive piston spring (486).
17. Use J 44764:  spring compressor and J 23327:  spring compressor to compress the overdrive clutch piston spring (486).
18. Install the overdrive clutch spring retainer (485).
19. Remove J 44764:  spring compressor and J 23327:  spring compressor.
Fig 9: Identifying Overdrive Clutch Components
Courtesy of GENERAL MOTORS CORP.
20. Install the overdrive clutch spacer (484).
21. Install the overdrive clutch plates. Starting with the overdrive clutch plates (483) with external splines. Alternating with the overdrive clutch plates (482) with internal splines. Refer to Clutch Plate Selection Specifications .
22. Install the overdrive backing plate (481).
23. Install the overdrive clutch retainer ring (480).
Fig 10: Measuring Distance Between Overdrive Clutch Backing Plate & Bottom Of Gage Bar
Courtesy of GENERAL MOTORS CORP.
24. Measure the distance between the overdrive clutch backing plate and the bottom of the gage bar. Measure three times in different locations on the backing plate. Record this as H1.
25. Apply 65 PSI (448.17 kPa) of air pressure to the specified port. Measure the distance between the overdrive clutch backing plate and the bottom of the gage bar. Measure three times in different locations on the backing plate. Record this as H2.
26. Subtract H2 from H1 this is the clutch pack travel. Refer to Clutch Piston Travel Specifications .
Fig 11: Identifying Overdrive Clutch Housing
Courtesy of GENERAL MOTORS CORP.
27. Install the overdrive clutch housing (15) into the case.
Fig 12: Measuring Dimension M
Courtesy of GENERAL MOTORS CORP.
28. Measure the distance from the bottom of the gauge bar to the top of the overdrive and intermediate clutch. Record this as M1.
29. Measure the distance from the bottom of the gage Bar to the bottom of the intermediate and overdrive retainer ring groove in the case. Record this as M2.
30. Subtract M2 from M1. This will be dimension M.
Fig 13: Measuring Intermediate & Overdrive Clutch Housing Retaining Ring
Courtesy of GENERAL MOTORS CORP.
31. Measure the intermediate and overdrive clutch housing retaining ring (14). Refer to Intermediate and Overdrive Clutch Housing Retaining Ring Specifications for the correct size washer.
Fig 14: Installing Overdrive Clutch Housing Retainer Ring
Courtesy of GENERAL MOTORS CORP.
WARNING: Use care when removing or installing the snap ring. Be sure the J 45126 snap ring pliers are installed properly onto the snap ring or bodily injury may occur.
NOTE: If housings is replaced a measurement must be taken for end play.
32. Using J 45126:  pliers install the intermediate and overdrive clutch housing retainer ring (14) into the case.