OVERDRIVE PLANETARY GEAR AND CLUTCH OVERHAUL

Gear And Clutch Disassembly

10. Check operation of one-way clutch in clutch drum.
    Hold drum and turn planetary shaft clockwise and
    counterclockwise. Shaft should turn clockwise freely
    but lock when turned counterclockwise. Replace one­
    way clutch if necessary.

11. Remove overdrive clutch from planetary gear (Pig.
    3).

10. Remove thrust bearing and race assembly from
    clutch drum (Fig. 4).

11. Measure stroke length of clutch piston as follows:

(a) Mount oil pump on torque converter. Then mount clutch on oil pump (Fig. 5).

(b) Mount dial indicator on clutch and position
indicator stylus on clutch piston (Fig. 6).

(c) Apply compressed air through clutch feed hole
in oil pump and note piston stroke length. Stroke
length should be 1.85 to 2.15 mm (.0728 to .0846 in).

10. Replace clutch pack retainer if stroke length is
    incorrect.Refer to chart in Specifications section for re­
    placement retainer thicknesses.

11. Remove clutch pack snap ring and remove the
    clutch pack.

12. Compress piston return spring with tool B.Vi. FM.
    27 and shop press and remove piston snap ring (Fig. 8).

13. Remove compressor tool and piston return springs.

14. Mount oil pump on converter. Then mount clutch
    on oil pump (Fig. 9).

10. Hold clutch piston by hand and apply compressed
    air through oil pump feed hole to ease piston out (Fig.
    9). Apply only enough air pressure to remove piston.

11. Remove bearing and race from ring gear (Fig. 10).

12. Remove snap ring from ring gear and remove ring
    gear hub (Fig. 11).

10. Remove race from planetary gear (Fig. 12).

11. Remove snap ring and remove retaining plate
    (Tig. 13).

12. Remove one-way clutch and outer race as assem­
    bly. Then separate race from clutch (Fig. 14).

13. Remove thrust washer (Fig. IS).

14. Measure clutch disc thickness. Minimum allow­
    able thickness is 1.84 mm (.0724 in).

CLUTCH DRUM

10. Measure free length of piston return springs with
    springs in retainer (Fig. 16>. Length should be 16.8 mm
    (.661 in).

11. Check clutch piston check ball (Fig. 17). Shake
    piston to see if ball moves freely. Then check ball seal­
    ing by applying low pressure compressed air to ball inlet
    as shown. Air should not leak past check ball.

12. Check inside diameter of clutch drum bushings
    with bore gauge (Fig. 18). Maximum inside diameter is
    27.11 mm (1.0673 in). Replace drum if bushing inside
    diameter is greater than specified.

Fig. 3 Removing Overdrive Clutch From Gear

Fig. 5 Assembling Converter, Pump And Clutch For T

(21) Check inside diameter of planetary gear bushing (Fig, 19). Maximum inside diameter is 11.27 rom (0.4437 in). Replace planetary gear if bushing inside diameter is greater then specified.

Gear And Clutch Assembly

10. Install thrust washer in planetary gear (Fig. 20).
    Grooved side of washer faces up and toward front.

11. Install one-way clutch in race (Fig. 21). Flanged
    side of clutch must face upward as shown.

12. Install assembled one-way clutch and outer race in
    planetary gear. Be sure flanged side of clutch is facing
    upward.

13. Install clutch pack retaining plate and snap ring
    in planetary gear.

10. Coat planetary race with petroleum jelly and in­
    stall it on planetary gear. Outside diameter of race is
    41.8 mm (1.646 in); inside diameter is 27.1 mm (1.067
    in).

11. Install hub in planetary ring gear and install snap
    ring.

12. Coat race and bearing with petroleum jelly and
    install in planetary ring gear (Fig. 22).

13. Verify bearing/race size. Outside diameter of race
    is 47.8 mm (1.882 in); inside diameter is 24.2 mm (.953
    in). Outside diameter of bearing is 46.8 mm (1.843 in);
    inside diameter is 26 mm (1.024 in).

(9) Lubricate and install new O-rings on clutch piston.
Then install piston in clutch drum.

(10) Install piston return springs in clutch piston (Fig.
23).

10. Install piston snap ring. Compress piston return
    springs with compressor tool and shop press (Fig. 24).

11. Install clutch pack in drum. Install steel plate
    first, then a disc (Fig. 25). Continue installation se­
    quence until required number of discs and plates have
    been installed.

12. Install clutch pack retainer with flat side facing
    downward. Then install retainer snap ring (Fig. 26).
    Compress springs with tool B.Vi. FM. 27.

13. Measure clutch piston stroke length again (refer
    to procedure outlined in disassembly procedure ). If
    stroke length is incorrect, install new clutch discs or
    select fit retainer. Retainer thicknesses are outlined in
    the Specifications section.

14. Install clutch drum bearing and race assembly
    (Fig. 27). Be sure bearing rollers face upward as shown.

Fig. 10 Removing Ring Gear Bearing And Race

Fig. 12 Remove Planetary Gear Race

Fig. 11 Removing Ring Gear Hub

Fig. 13 Removing Snap Ring And Retaining Plate

Outside diameter of assembled bearing and race is 50.2 mm (1.976 in). Inside diameter is 28.9 mm (1.138 in). (16) Install clutch on planetary gear.

(17) Verify one-way clutch operation. Hold drum and turn planetary shaft clockwise and counterclockwise. Shaft should turn clockwise freely but lock when turned counterclockwise.

Fig. 14 Removing One-Way Clutch

Fig. 16 Checking Piston Return Spring Length

Fig. 17 Testing Clutch Piston Check Ball

Fig. 18 Checking Clutch Drum Bushings

Fig. 19 Checking Planetary Bushing

Fig. 20 Install Planetary Thrust Washer

Fig. 24 Installing Clutch Piston Snap Ring

Fig. 23 Installing Piston Return Springs

Fig. 25 Installing Clutch Discs And Plates

Fig. 27 Installing Clutch Drum Bearing And Race Assembly

Fig. 26 Installing Retainer And Snap Ring

OVERDRIVE SUPPORT OVERHAUL

Support Disassembly

10. Check brake piston operation. Mount support on
    clutch (Fig. 2).

11. Apply compressed air through support feed hole
    and observe brake piston movement (Fig. 2). Piston
    should move smoothly and not bind or stick. If operation
    is incorrect, replace piston and support.

12. Remove thrust bearing front race, thrust bearing
    and rear race (Fig. 3).

10. Turn overdrive support over and remove bearing
    race and clutch drum thrust washer (Fig. 4).

11. Compress piston return spring with tool B.Vi. FM.
    26 and remove piston snap ring (Fig. 5).

12. Mount support in direct clutch and remove brake
    piston with compressed air. Apply air to same feed hole
    used when checking piston operation.

13. Remove and discard support O-rings (Fig. 1).

14. Remove support seal rings (Fig. 6).

Fig. 2 Checking Brake Piston Movement

Fig. 3 Removing Support Thrust Bearing And Races

(9) Measure free length of piston return springs with
springs mounted in retainer (Fig. 7). Length should be
18.61 mm (.733 in).

10. Clean support components and dry them with
    compressed air.

11. Inspect overdrive support and brake piston. Re­
    place support and piston if either part is worn or dam-

Fig. 4 Removing Clutch Drum Thrust Washer And Ïàñå

Assembling Overdrive Support

10. Lubricate new support seal rings. Then compress
    rings and install them on support {Fig. 8).

11. Lubricate and install new O-rings on brake piston.
    Then carefully seat piston in support.

12. Install return springs on brake piston.

    Fig. 6 Removing Support Seal Rings

    
    

13. Compress return springs with tool (Fig. 5) and
    install piston snap ring.

14. Install support bearing race and clutch drum
    thrust washer (Fig. 4).

15. Install thrust bearing and front and rear bearing
    races. Thrust bearing rollers should face upward as
    shown (Fig. 9).

(7) Verify thrust bearing/race sizes (Fig. 9). Front race outer diameter is 47.8 mm (1.882 in); inside diameter is 30.7 mm (1.209 in). Rear race outer diameter is 47.8 mm

(1.882 in); inside diameter is 34.3 mm (1.350 in). Bear­ing outer diameter is 47.7 mm (1.878 in); inside diam­eter is 32.7 mm (1.287 in).

(8) Verify brake piston operation. Use same procedure described at beginning of disassembly. Piston should operate smoothly and not bind or stick.

Fig. 8 Installing Support Seal Rings

Fig. 9 Installing Support Thrust Bearing And Races

Clutch Disassembly

(DRemove direct clutch from forward clutch (Fig. 2). (2) Remove clutch drum thrust washer (Fig. 3).

10. Check clutch piston stroke length as outlined in
    following steps.

11. Mount direct clutch on overdrive support assembly
    (Fig. 41.

12. Mount dial indicator on clutch and position indi­
    cator plunger on clutch piston (Fig. 4).

13. Apply 57-114 psi air pressure through feed hole in
    overdrive support and note piston stroke length iFig. 5).
    Check stroke at least twice.

14. Piston stroke length should be 1.37 mm to 1.60 mm
    (.0539 to .0642 in). If stroke length is incorrect, either
    the clutch pack retainer or clutch discs will have to be
    replaced.

DIRECT ClUTCH

10. Compress clutch springs with tool B.Vi. FM. 27.
    Remove clutch pack snap ring and remove retainer and
    clutch pack from drum (Fig. 6).

11. Compress clutch piston return springs with tool
    B.Vi. FM. 27 and remove clutch piston snap ring (Fig.
    7).

10. Remove compressor tool and return spring.

11. Remove clutch piston. Remount clutch on over­
    drive support (Fig. 8). Apply compressed air through
    piston feed hole in support to remove piston. Use only
    enough air to ease piston out.

Fig. 4 Mount Direct Clutch On Overdrive Support

Fig. 6 Removing Clutch Pack Snap Ring

Fig. 5 Checking Direct Clutch Piston Stroke Length

Fig. 7 Removing Piston Return Spring Snap Ring

10. 
    
    Remove and discard clutch piston O-rings.

11. Measure clutch disc thickness. Minimum allow­
    able thickness is 1.84 mm (.0724 in). Replace discs if
    below minimum thickness.

12. Measure free length of piston return springs with
    springs in retainer (Fig. 9). Length should be 21.32 mm
    (.839 in). Replace return springs if not within specifi­
    cation.

13. Check clutch piston check ball (Fig. 10). Shake
    piston to see if ball moves freely. Then check ball seat­
    ing by applying low pressure compressed air to ball inlet
    as shown. Air should not leak past check ball.

(16) Measure inside diameter of clutch drum bushing. Inside diameter should be no more than 53.97 mm (2.1248 in). Replace drum if bushing inside diameter is greater than specified.

Direct Clutch Assembly

10. Lubricate and install replacement O-rings on
    clutch piston.

11. Install clutch piston in drum and install return
    springs on piston.

12. Compress piston return springs and install snap
    ring (Fig. 7). Be sure snap ring end gap is not aligned
    with spring retainer tab.

13. Install clutch discs and plates (Fig. 11). Install
    plate then disc until all plates and discs are installed.
    Use four plates and discs in 6-cyl. transmissions and
    three plates and discs in 4-cyl. transmissions.

14. Install clutch pack retainer in drum (Fig. 12).

15. Install clutch pack snap ring (Fig. 12).

16. Check snap ring position. If necessary, shift snap
    ring until end gap is not aligned with any notches in
    clutch drum (Fig. 12).

17. Check clutch piston stroke length a second time.
    If length is OK, continue with assembly. If stroke length
    is incorrect, replace clutch discs or use different thick­
    ness clutch pack retainer (Fig. 12). See Specifications
    section for retainer thicknesses.

18. Lubricate clutch drum thrust washer with petro­
    leum jelly and install it in drum (Fig. 3).

10. Mount direct clutch assembly on forward clutch
    assembly and check assembled height (Fig. 14). Height
    should be 70.3 to 71.5 mm (2.767 to 2.815 in).

11. If assembled height is incorrect, clutches are not
    seated.

Fig. 9 Checking Piston Return Spring Length

Fig. 10 Testing Piston Check Ball Seating

(12) If clutch height is OK, remove direct clutch from forward clutch and proceed to forward clutch overhaul.

Fig. 11 Installing Direct Clutch Discs And Plates

Fig. 13 Adjusting Clutch Pack Snap Ring Position

Fig. 12 Install Clutch Pack Retainer

Fig. 14 Checking Direct Clutch Assembled Height

FORWARD CLUTCH OVERHAUL

Fig. 1 Forward Clutch Components

59

Forward Clutch Disassembly

(1) Check clutch piston stroke as outlined in following
steps.

10. Position overdrive support on wood blocks and
    mount forward clutch drum on support (Fig. 2).

11. Remove bearing and race from forward clutch
    drum (Fig. 2).

(4) Mount dial indicator on clutch drum. Position dial
indicator plunger against clutch piston (Fig. 3).

THRUST BEARING BEARING RACE

Fig. 2 Positioning Drum And Support On Wood Blocks

10. Apply compressed air through right side feed hole
    in support and note piston stroke length on dial indi­
    cator.

11. Stroke length should be: 3.73 to 4.59 mm (.1469 to
    .1807 in) on 6-cyl. transmissions and 3.42 to 4.23 mm
    (.1346 to .1665 in) on 4-cyl. transmissions.

12. Replace clutch discs if stroke length is incorrect.

13. Remove clutch pack snap ring and remove retainer
    and clutch pack (Fig. 4).

14. Remove clutch pack cushion plate (Fig. 5).

10. Compress clutch springs with tool B.Vi. FM. 27
    and remove piston snap ring.

11. Remove spring compressor tool and piston return
    springs.

Fig. 3 Checking Forward Clutch Piston Stroke Length

Fig. 5 Removing Cushion Plate