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Technical Service Information: Component Rebuild Section
Technical Service Information: Component Rebuild Section
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12
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COMPLETED END COVER ASSEMBLY
Continued on Page 43
4
DIRECT CLUTCH
HOUSING ASSEMBLY
REVERSE CLUTCH
HOUSING ASSEMBLY
Continued on Page 44
9
7 8
10
14 15
12
13
11
7 DIRECT CLUTCH BACKING PLATE "SELECTIVE" SNAP RING. 13 DIRECT CLUTCH PISTON RETURN SPRING.
8 DIRECT CLUTCH BACKING PLATE. 14 DIRECT CLUTCH APPLY PISTON.
9 DIRECT CLUTCH FRICTION PLATES (3 REQUIRED). 15 DIRECT CLUTCH HOUSING.
10 DIRECT CLUTCH STEEL PLATES (3 REQUIRED).
11 DIRECT CLUTCH BALANCE PISTON SNAP RING.
12 DIRECT CLUTCH BALANCE PISTON.
7
11
12
8
13
14
9
10
15
15
11 DIRECT CLUTCH BALANCE PISTON SNAP RING. 7 DIRECT CLUTCH BACKING PLATE "SELECTIVE" SNAP RING.
12 DIRECT CLUTCH BALANCE PISTON. 8 DIRECT CLUTCH BACKING PLATE.
13 DIRECT CLUTCH PISTON RETURN SPRING. 9 DIRECT CLUTCH FRICTION PLATES (3 REQUIRED).
14 DIRECT CLUTCH APPLY PISTON. 10 DIRECT CLUTCH STEEL PLATES (3 REQUIRED).
15 DIRECT CLUTCH HOUSING. 15 DIRECT CLUTCH HOUSING.
Copyright © 2004 ATSG Copyright © 2004 ATSG
Figure 77 Figure 78
44 AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
COMPONENT REBUILD SECTION COMPONENT REBUILD SECTION
DIRECT CLUTCH HOUSING ASSEMBLY (CONT'D) REVERSE CLUTCH HOUSING ASSEMBLY
12. Turn the direct clutch housing over and tap on 1. Disassemble the reverse clutch housing using
flat work surface to seat snap ring to the top of Figure 81 as a guide.
the groove. 2. Inspect the bushing area, and the ball capsules
13. Install dial indicator, as shown in Figure 79, for proper operation in reverse clutch housing,
with the plunger resting on backing plate, and as shown in Figure 80.
zero the dial indicator. Note: Refer to Page 40 for more information.
14. Lift both sides of clutch pack with scribes to 3. Install the reverse clutch molded piston into
measure for proper clutch pack clearance. reverse clutch housing, as shown in Figure 82.
15. The direct clutch pack clearance should be, Note: There are two different dimension
1.0 to 1.3 mm (.040" to .051"), as shown in reverse clutch molded pistons, as shown in
Figure 79. Figure 82. Ensure that you are installing
16. Change the selective snap ring as necessary to the proper piston for model you are building.
obtain the specified clutch clearance. 4. Install the reverse clutch piston "Bellville"
17. Set the completed direct clutch housing aside return spring, as shown in Figure 82.
while we rebuild the reverse clutch housing. 5. Install the bellville return spring retainer, as
shown in Figure 82.
6. Compress the bellville spring and retainer and
install snap ring, as shown in Figure 82, and
ensure snap ring is fully seated.
DIRECT CLUTCH CLEARANCE SHOULD BE
1.0 - 1.3 MM (.040" - .051") Continued on Page 47
DIAL
INDICATOR
0
10 10
20 20
30 30
40 40
50 0 50
INSPECT
BUSHING INSPECT
BALL CAPSULE
INSPECT
BALL CAPSULE
16 17 18
6
19
24
23
20 22
21
1 REAR SUN GEAR ASSEMBLY RETAINING SNAP RING. 18 REVERSE CLUTCH FRICTION PLATES (2 REQUIRED).
2 REAR SUN GEAR ASSEMBLY. 19 REVERSE CLUTCH STEEL PLATES (2 REQUIRED).
3 REAR SUN GEAR TO DIRECT HUB, NO. 3, THRUST BEARING. 20 REVERSE CLUTCH PISTON BELLVILLE RETAINER SNAP RING.
4 DIRECT CLUTCH HUB. 21 REVERSE CLUTCH PISTON BELLVILLE SPRING RETAINER.
5 DIRECT HUB TO DIRECT HOUSING, NO. 2, THRUST BEARING. 22 REVERSE CLUTCH PISTON BELLVILLE RETURN SPRING.
6 DIRECT CLUTCH HOUSING ASSEMBLY, COMPLETE. 23 REVERSE CLUTCH PISTON.
16 REVERSE CLUTCH BACKING PLATE "SELECTIVE" SNAP RING. 24 REVERSE CLUTCH HOUSING ASSEMBLY.
17 REVERSE CLUTCH BACKING PLATE. Copyright © 2004 ATSG
Figure 81
46 AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
REVERSE CLUTCH HOUSING ASSEMBLY (CONT'D)
FORD PISTON MAZDA PISTON 7. Install the reverse clutch plates beginning with
XS4Z-7D402-AB FN01-19-SHOA
a steel plate and alternating with friction plates
until you have installed two of each, as shown
in Figure 83.
"A" "A"
Note: Friction plates should be soaked in
Mercon® V fluid for 15 minutes prior to
installation.
DIMENSION "A" = 1.475" DIMENSION "A" = 1.375"
Continued on Page 48
16
20
21
17
22
23
18
19
24
24
20 REVERSE CLUTCH PISTON BELLVILLE RETAINER SNAP RING. 16 REVERSE CLUTCH BACKING PLATE "SELECTIVE" SNAP RING.
21 REVERSE CLUTCH PISTON BELLVILLE SPRING RETAINER. 17 REVERSE CLUTCH BACKING PLATE.
22 REVERSE CLUTCH PISTON BELLVILLE RETURN SPRING. 18 REVERSE CLUTCH FRICTION PLATES (2 REQUIRED).
23 REVERSE CLUTCH PISTON. 19 REVERSE CLUTCH STEEL PLATES (2 REQUIRED).
24 REVERSE CLUTCH HOUSING ASSEMBLY. 24 REVERSE CLUTCH HOUSING ASSEMBLY.
Copyright © 2004 ATSG Copyright © 2004 ATSG
Figure 82 Figure 83
FEELER
GAUGE
COMPLETED
REVERSE CLUTCH
HOUSING ASSEMBLY
Continued on Page 50
NUMBER 2
DIRECT CLUTCH
THRUST BEARING
COMPLETED DIRECT/REVERSE
CLUTCH HOUSING ASSEMBLY
DIRECT CLUTCH
HUB AND BEARING
ASSEMBLY
Continued on Page 52
Copyright © 2004 ATSG
Figure 88
50 AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
PLANETARY GEAR TRAIN EXPLODED VIEW
10 11
13
12
14
17
16
15
21 18
19 20 19
DO NOT REMOVE
THIS SNAP RING
10 REAR PLANETARY CARRIER RETAINING SNAP RING. 16 FRONT PLANETARY CARRIER/REAR RING GEAR ASSEMBLY.
11 REAR PLANETARY CARRIER ASSEMBLY. 17 FRONT PLANETARY CARRIER RING GEAR AND HUB ASSEMBLY.
12 FRONT PLANETARY SUN GEAR THRUST BEARING (NUMBER 5). 18 FRONT RING GEAR AND HUB ASSEMBLY (REAR VIEW).
13 FRONT PLANETARY SUN GEAR. 19 LOW SPRAG ASSEMBLY END BEARINGS (2 REQUIRED).
14 FRONT PLANETARY SUN GEAR SNAP RING (CIR-CLIP). 20 LOW SPRAG CAGE ASSEMBLY.
15 FRONT PLANETARY CARRIER THRUST BEARING (NUMBER 6). 21 LOW SPRAG RETAINER.
Copyright © 2004 ATSG
Figure 90
20 Continued on Page 52
Tab With
19 Flat Side
Facing Up
Windows
DO NOT REMOVE Facing Left
THIS SNAP RING
18 Figure 92
Continued on Page 54
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16
14
10
16
11
12
17
SPACERS
"O" RING
SEALS
DETENT SPRING
PARKING PAWL
MANUAL CONTROL SHAFT
ACTUATING ROD
11
12
10
9
(SOME MODELS)
15
8 7
8
14
1 2 3
13
16
4 17
19 18
2 3
7 6
5
Upper and Lower Valve Bodies
Found on Page 57
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