Overdrive/Direct Clutch Assembly
Overdrive/Direct Clutch AssemblySpecial Tool(s):
Disassembly
1. Remove the overdrive clutch snap ring.
2. Remove the overdrive clutch hub and clutch assembly.
3. Remove the bottom overdrive clutch steel plate.
4. Remove the No. 2 rear sun gear thrust bearing.
5. Install the special tools on the balance piston.
6. Using the special tools, compress the overdrive piston return spring and remove the balance piston snap ring.
7. Remove the special tools.
8. Remove and discard the balance piston.
9. Remove the overdrive piston return spring.
10. Position the overdrive/direct clutch assembly in the rear cover.
11. Apply air pressure to the overdrive piston port on the rear cover and remove the overdrive piston.
1 Low/Reverse piston fluid port
2 Overdrive piston fluid port
3 Intermediate piston fluid port
4 Direct piston fluid port
5 Lubrication
12. Remove the overdrive/direct clutch assembly from the rear cover.
13. Remove and discard the overdrive clutch piston inner seals.
14. Remove and discard the overdrive clutch piston outer seals from the piston.
15. Install the special tools on the direct clutch cylinder.
16. CAUTION: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off of the snap ring. If the piston is compressed too far, the piston alignment tab can be broken off.
Using the special tools, compress the direct clutch piston return spring, and remove the snap ring.
17. Remove the special tools and the direct clutch cylinder.
18. Remove the rear direct clutch piston seal.
19. Remove and discard the direct clutch piston.
20. Remove the direct clutch piston return spring.
21. Remove and discard the direct clutch piston seals.
22. Remove the direct clutch snap ring.
23. Remove the direct clutch pressure plate, clutch assembly and wave spring.
24. Clean and inspect the overdrive/direct clutch hub and shaft assembly for damage. Install new if necessary.
Assembly
1. Install the direct clutch wave spring.
2. Lubricate the direct clutch pack in clean automatic transmission fluid.
3. Install the direct clutch assembly and pressure plate.
4. Install the direct clutch snap ring.
5. Install new direct clutch piston seals and lubricate the seals with petroleum jelly.
6. Install the direct clutch piston return spring.
7. Lubricate a new direct clutch piston with petroleum jelly and install the piston.
8. Install a new rear direct clutch piston seal and lubricate it with petroleum jelly.
9. NOTE: Align the tab on the direct clutch cylinder with the slot on the overdrive/direct clutch hub and shaft assembly.
Install the direct clutch cylinder and position the special tools on the cylinder.
10. CAUTION: Only compress the direct clutch piston return spring far enough to install the direct clutch cylinder snap ring. If the piston is compressed too far, the piston alignment tab can be broken off.
Using the special tools, compress the direct clutch piston return spring and install the snap ring.
11. Remove the special tools.
12. Install new seals on the overdrive clutch piston and lubricate the seals with petroleum jelly.
13. Install new overdrive clutch piston inner seals and lubricate the seals with petroleum jelly.
14. Install the overdrive clutch piston in the overdrive/direct clutch hub and shaft assembly and push the overdrive clutch piston in the cylinder by hand using the special tool.
15. NOTE: Install the overdrive clutch piston return spring so that the holes are facing up.
Install the overdrive clutch piston return spring.
16. Lubricate the seals on a new balance piston.
17. Install a new balance piston.
18. Install the special tools on the balance piston.
19. Using the special tool, press the balance piston down and install the snap ring.
20. Remove the special tools from the balance piston.
21. Install the No. 2 rear sun gear thrust bearing.
22. Install the overdrive clutch hub.
23. Lubricate the overdrive clutch pack in clean automatic transmission fluid.
24. Install the overdrive clutch pack assembly and the pressure plate.
25. Install the overdrive clutch pack snap ring.
26. Position the overdrive/direct clutch assembly in the cover assembly, install a dial indicator and position the plunger on the overdrive clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the overdrive clutch piston port while recording the clutch pack clearance on the dial indicator. The clearance should be between 1.13 mm (0.04 inch) and 2.28 mm (0.08 inch). If the clearance is out of range, check the overdrive clutch pack for correct installation. If the overdrive clutch pack is correctly installed, install a new overdrive clutch pack.
27. Position the plunger on the direct clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the direct clutch piston port while recording the clutch pack clearance on the dial indicator. The clearance should be between 0.98 mm (0.03 inch) and 2.34 mm (0.08 inch). If the clearance is out of range, check the direct clutch pack for correct installation. If the direct clutch pack is correctly installed, install a new direct clutch pack.
