Input Clutch Assembly: Assembly

Use petrolatum on all seals to ease assembly of components.

1. Using an arbor press, install input shaft to input shaft hub (Fig 1).
   Fig 1: Installing Input Shaft

   Courtesy of DAIMLERCHRYSLER CORP.
2. Install input shaft snap ring (Fig 2).
   Fig 2: Installing Input Shaft Snap Ring

   Courtesy of DAIMLERCHRYSLER CORP.
3. Using an arbor press and Tool 6057, Install OD/Reverse piston return spring and snap ring (Fig 3) (Fig 4).
   Fig 3: Identifying Return Spring And Snap Ring

   Courtesy of DAIMLERCHRYSLER CORP.
   Fig 4: Installing Snap Ring

   Courtesy of DAIMLERCHRYSLER CORP.
4. Install the OD/Reverse piston assembly to the input clutch retainer as shown in (Fig 5).
   Fig 5: Installing Od/Reverse Piston

   Courtesy of DAIMLERCHRYSLER CORP.
5. Install the input hub/shaft assy, to the OD/Reverse piston/clutch retainer assy. (Fig 6).
   Fig 6: Installing Input Shaft Hub Assembly

   Courtesy of DAIMLERCHRYSLER CORP.
6. Install input hub tapered snap ring (Fig 7) (Fig 8).
   Fig 7: Installing Input Hub Tapered Snap Ring

   Courtesy of DAIMLERCHRYSLER CORP.
   Fig 8: Removing Input Clutch Hub, Retainer, And Od/Reverse Piston

   Courtesy of DAIMLERCHRYSLER CORP.
7. Install UD clutch piston (Fig 9).
   Fig 9: Installing Underdrive Clutch Piston

   Courtesy of DAIMLERCHRYSLER CORP.
8. Install UD piston return spring and Tool 5067 as shown in (Fig 10).
   Fig 10: Installing Seal Compressor Special Tool 5067

   Courtesy of DAIMLERCHRYSLER CORP.
9. Using Tool 5059A and an arbor press, Install the UD spring retainer and snap ring (Fig 11) (Fig 12) (Fig 13) Compress just enough to install snap ring.
   CAUTION: Compress return spring just enough to install snap ring.
   Fig 11: Installing UD Return Spring And Retainer

   Courtesy of DAIMLERCHRYSLER CORP.
   Fig 12: Installing UD Spring Retainer And Snap Ring

   Courtesy of DAIMLERCHRYSLER CORP.
   Fig 13: Removing Underdrive Clutch Piston, Spring And Retainer

   Courtesy of DAIMLERCHRYSLER CORP.
10. Install the UD clutch pack. Leave out upper disc, until snap ring is installed (Fig 14).
    Fig 14: Installing Underdrive Clutch Pack

    Courtesy of DAIMLERCHRYSLER CORP.
11. Install the UD clutch flat snap ring (Fig 15).
    Fig 15: Installing Ud Clutch Flat Snap Ring

    Courtesy of DAIMLERCHRYSLER CORP.
12. Install the last UD clutch disc (Fig 16).
    Fig 16: Installing Last Ud Clutch Disc

    Courtesy of DAIMLERCHRYSLER CORP.
13. Install the OD/UD clutch reaction plate and snap ring (Fig 17) (Fig 18). The OD/UD clutches reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up.
    Fig 17: Installing Od/Ud Reaction Plate

    Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: Snap ring ends must be located within one finger of the input clutch hub. Be sure that snap ring is fully seated, by pushing with screwdriver, into snap ring groove all the way around.
    Fig 18: Identifying Tapered Snap Ring

    Courtesy of DAIMLERCHRYSLER CORP.
14. Seat tapered snap ring to ensure proper installation (Fig 19) (Fig 20).
    Fig 19: Identifying Seating Tapered Snap Ring

    Courtesy of DAIMLERCHRYSLER CORP.
15. Install input clutch assembly to the Input Clutch Pressure Fixture-Tool 8391 (Fig 21).
16. Set up dial indicator on the UD clutch pack as shown in (Fig 22).
17. Using moderate pressure, press down and hold (near indicator) the UD clutch pack with screwdriver or suitable tool and zero dial indicator (Fig 23). When releasing pressure on clutch pack, indicator reading should advance 0.005-0.010.
    CAUTION: Do not apply more than 30 psi (206 kPa) to the underdrive clutch pack.
18. Apply 30 psi (206 kPa) to the underdrive hose on Tool 8391 and measure UD clutch clearance. Measure and record UD clutch pack measurement in four (4) places, 90° apart.
19. Take average of four measurements and compare with UD clutch pack clearance specification. Underdrive clutch pack clearance must be 0.94-1.50 mm (0.037-0.059 in.). 
20. If necessary, select the proper reaction plate to achieve specifications:
    UNDERDRIVE REACTION PLATE THICKNESS
    
    

    UNDERDRIVE REACTION PLATE THICKNESS
    4659939AB	5.837-5.937 mm (0.230-0.234 in.)
    4659940AB	6.147-6.248 mm (0.242-0.246 in.)
    4659941AB	6.457-6.557 mm (0.254-0.258 in.)

21. Install the OD clutch pack (four frictions/three steels) (Fig 24).
    Fig 20: Exploded View Of Underdrive Clutch Assembly

    Courtesy of DAIMLERCHRYSLER CORP.
    Fig 21: Identifying Input Clutch Assembly On Pressure Fixture Tool 8391

    Courtesy of DAIMLERCHRYSLER CORP.
    Fig 22: Setting Up Dial Indicator To Measure Ud Clutch Clearance

    Courtesy of DAIMLERCHRYSLER CORP.
    Fig 23: Pressing Down On UD Clutch Pack And Zero Dial Indicator

    Courtesy of DAIMLERCHRYSLER CORP.
    Fig 24: Installing OD Clutch Pack

    Courtesy of DAIMLERCHRYSLER CORP.
22. Install OD pressure plate waved snap ring (Fig 25).
    Fig 25: Installing Waved Snap Ring

    Courtesy of DAIMLERCHRYSLER CORP.
23. Install the OD/Reverse pressure plate with large step down (towards OD clutch pack) (Fig 26).
    Fig 26: Installing OD/Reverse Pressure Plate

    Courtesy of DAIMLERCHRYSLER CORP.
24. Install OD pressure plate flat snap ring (Fig 27) (Fig 28).
    Fig 27: Installing Flat Snap Ring

    Courtesy of DAIMLERCHRYSLER CORP.
    Fig 28: Exploded View Of Overdrive Clutch Assembly

    Courtesy of DAIMLERCHRYSLER CORP.
25. Measure OD clutch pack clearance. Set up dial indicator on top of the OD/Reverse pressure plate as shown in (Fig 29).
    Fig 29: Measuring Dial Indicator OD Clutch Pack Clearance

    Courtesy of DAIMLERCHRYSLER CORP.
26. Zero dial indicator and apply 30 psi (206 kPa) air pressure to the overdrive clutch hose on Tool 8391. Measure and record OD clutch pack measurement in four (4) places, 90° apart.
27. Take average of four measurements and compare with OD clutch pack clearance specification. The overdrive (OD) clutch pack clearance is 1.07-3.25 mm (0.042-0.128 in.). 

    If not within specifications, the clutch is not assembled properly. There is no adjustment for the OD clutch clearance.

28. Install reverse clutch pack (two frictions/one steel) (Fig 30).
    Fig 30: Installing Reverse Clutch Pack

    Courtesy of DAIMLERCHRYSLER CORP.
29. Install reverse clutch reaction plate with the flat side down towards reverse clutch (Fig 31).
    Fig 31: Installing Reaction Plate

    Courtesy of DAIMLERCHRYSLER CORP.
30. Tap reaction plate down to allow installation of the reverse clutch snap ring. Install reverse clutch snap ring (Fig 32) (Fig 33).
    Fig 32: Installing Reverse Clutch Snap Ring

    Courtesy of DAIMLERCHRYSLER CORP.
31. Pry up reverse reaction plate to seat against snap ring (Fig 34).
    Fig 33: Identifying Reverse Clutch Assembly

    Courtesy of DAIMLERCHRYSLER CORP.
    Fig 34: Seating Against Snap Ring Pry Up Reaction Plate

    Courtesy of DAIMLERCHRYSLER CORP.
32. Set up a dial indicator on the reverse clutch pack as shown in (Fig 35).
    Fig 35: Setting Dial Indicator

    Courtesy of DAIMLERCHRYSLER CORP.
33. Using moderate pressure, press down and hold (near indicator) reverse clutch disc with screwdriver or suitable tool and zero dial indicator (Fig 36). When releasing pressure, indicator should advance 0.005-0.010. as clutch pack relaxes.
34. Apply 30 psi (206 kPa) air pressure to the reverse clutch hose on Tool 8391. Measure and record reverse clutch pack measurement in four (4) places, 90° apart.
35. Take average of four measurements and compare with reverse clutch pack clearance specification. The reverse clutch pack clearance is 0.89-1.37 mm (0.035-0.054 in.).  Select the proper reverse clutch snap ring to achieve specifications:
    REVERSE CLUTCH SNAP RING THICKNESS
    
    

    REVERSE CLUTCH SNAP RING THICKNESS
    4377195	1.53-1.58 mm (0.060-0.062 in.)
    4412871	1.77-1.83 mm (0.070-0.072 in.)
    4412872	2.02-2.07 mm (0.080-0.082 in.)
    4412873	2.27-2.32 mm (0.090-0.091 in.)

    Fig 36: Pressing Down On Reverse Clutch And Zero Indicator

    Courtesy of DAIMLERCHRYSLER CORP.
36. To complete the assembly, reverse clutch and overdrive clutch must be removed.
37. Install the #2 needle bearing (Fig 37).
    Fig 37: Installing No. 2 Needle Bearing

    Courtesy of DAIMLERCHRYSLER CORP.
38. Install the underdrive shaft assembly (Fig 38).
    Fig 38: Installing Underdrive Shaft Assembly

    Courtesy of DAIMLERCHRYSLER CORP.
39. Install the #3 thrust washer to the underdrive shaft assembly. Be sure five tabs are seated properly (Fig 39).
    Fig 39: Installing No. 3 Thrust Washer

    Courtesy of DAIMLERCHRYSLER CORP.
40. Install the #3 thrust plate to the bottom of the overdrive shaft assembly. Retain with petrolatum or transmission assembly gel (Fig 40).
    Fig 40: Installing No. 3 Thrust Plate

    Courtesy of DAIMLERCHRYSLER CORP.
41. Install the overdrive shaft assembly (Fig 41) (Fig 42).
    Fig 41: Installing Overdrive Shaft Assembly

    Courtesy of DAIMLERCHRYSLER CORP.
42. Reinstall overdrive and reverse clutch as shown. Rechecking these clutch clearances is not necessary. 

Fig 42: Identifying Overdrive/Underdrive Shafts

Courtesy of DAIMLERCHRYSLER CORP.