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Home › Chrysler › 2002 › PT Cruiser Base, Automatic › Repair and Diagnosis › Transmission › Automatic Trans › Automatic Transmission - Overhaul › Input Clutch Assembly › Disassembly

Input Clutch Assembly: Disassembly

  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
    G01044369Courtesy of DAIMLERCHRYSLER CORP.
  3. Remove reverse clutch snap ring (Fig 2).
    Fig 2: Removing Reverse Clutch Snap Ring
    G01044370Courtesy of DAIMLERCHRYSLER CORP.
  4. Pry up and remove reverse clutch reaction plate (Fig 3) (Fig 4).
    Fig 3: Removing Reverse Clutch Reaction Plate (1 Of 2)
    G01044371Courtesy of DAIMLERCHRYSLER CORP.
    Fig 4: Removing Reverse Clutch Reaction Plate (2 Of 2)
    G01044372Courtesy 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
    G01044373Courtesy of DAIMLERCHRYSLER CORP.
  6. Remove the OD/Reverse pressure plate snap ring (Fig 6).
    Fig 6: Removing OD/Reverse Pressure Plate Snap Ring
    G01044374Courtesy of DAIMLERCHRYSLER CORP.
  7. Remove OD/Reverse pressure plate (Fig 7).
    Fig 7: Removing OD/Reverse Pressure Plate
    G01044375Courtesy of DAIMLERCHRYSLER CORP.
  8. Remove OD/Reverse pressure plate wave snap ring (Fig 8).
    Fig 8: Removing Waved Snap Ring
    G01044376Courtesy 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 Overdrive (OD) Clutch Pack (1 Of 2)
    G01044377Courtesy of DAIMLERCHRYSLER CORP.
    Fig 10: Removing Overdrive (OD) Clutch Pack (2 Of 2)
    G01044378Courtesy of DAIMLERCHRYSLER CORP.
  10. Remove and inspect #3 & #4 thrust washers (Fig 11).
    Fig 11: Removing No. 3 & 4 Thrust Washers
    G01044379Courtesy of DAIMLERCHRYSLER CORP.
  11. Remove the underdrive shaft assembly (Fig 12).
    Fig 12: Removing Underdrive Shaft Assembly
    G01044380Courtesy of DAIMLERCHRYSLER CORP.
  12. Remove the #2 needle bearing (Fig 13).
    Fig 13: Removing No. 2 Needle Bearing
    G01044381Courtesy of DAIMLERCHRYSLER CORP.
  13. Remove the OD/UD reaction plate tapered snap ring (Fig 14).
    Fig 14: Removing OD/UD Reaction Plate Tapered Snap Ring
    G01044382Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: The OD/UD clutch reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up.
  14. Remove the OD/UD reaction plate (Fig 15).
    Fig 15: Removing OD/UD Reaction Plate
    G01044383Courtesy of DAIMLERCHRYSLER CORP.
  15. Remove the first UD clutch disc (Fig 16).
    Fig 16: Removing First UD Clutch Disc
    G01044384Courtesy of DAIMLERCHRYSLER CORP.
  16. Remove the UD clutch flat snap ring (Fig 27).
    Fig 17: Removing UD Clutch Flat Snap Ring
    G01044385Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: Tag underdrive clutch pack for reassembly identification.
  17. Remove the UD clutch pack (Fig 18).
    Fig 18: Removing Underdrive Clutch Pack
    G01044386Courtesy 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 UD Spring Retainer Snap Ring
    G01044387Courtesy of DAIMLERCHRYSLER CORP.
  19. Remove spring retainer (Fig 20).
    Fig 20: Removing UD Return Spring & Retainer
    G01044388Courtesy of DAIMLERCHRYSLER CORP.
  20. Remove UD clutch piston (Fig 21).
    Fig 21: Removing Underdrive Clutch Piston
    G01044389Courtesy of DAIMLERCHRYSLER CORP.
  21. Remove input hub tapered snap ring (Fig 22).
    Fig 22: Removing Input Hub Tapered Snap Ring
    G01044390Courtesy 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: Tapping On Input Hub
    G01044391Courtesy of DAIMLERCHRYSLER CORP.
    Fig 24: Removing Input Hub
    G01044392Courtesy of DAIMLERCHRYSLER CORP.
  23. Separate clutch retainer from OD/Reverse piston (Fig 25).
    Fig 25: Pulling Retainer From Piston
    G01044393Courtesy 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
    G01044394Courtesy of DAIMLERCHRYSLER CORP.
    Fig 27: Removing Snap Ring & Return Spring
    G01044395Courtesy of DAIMLERCHRYSLER CORP.
  25. Remove input shaft to input clutch hub snap ring (Fig 28).
    Fig 28: Removing Input Shaft Snap Ring
    G01044396Courtesy 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
    G01044397Courtesy of DAIMLERCHRYSLER CORP.
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