C. Direct Clutch Assembly

Measure

- Tool Required:
- J 7872 Magnetic Base Indicator Set





- Direct clutch piston stroke before disassembly using a J 7872. Temporarily install the direct clutch assembly onto the fluid pump and place the J 7872 plunger on the direct clutch piston. Apply 392 to 785 kPa (57 to 114 psi) of compressed air into the direct clutch apply passage of the fluid pump and observe the J 7872. Standard direct clutch piston stroke should fall within 1.12 to 1.52 mm (0.0441 to 0.0598 inch). If direct clutch piston stroke is greater or less than specified, inspect all direct clutch components for excessive wear.

REMOVE OR DISCONNECT

- Tool Required:
- J 23327 Clutch Spring Compressor





1. Direct clutch snap ring from direct clutch drum.





2. Direct clutch flange, three discs and three plates from direct clutch drum.





3. Direct clutch piston return spring snap ring from direct clutch piston return spring retainer using a J 23327 and a hydraulic press.





4. Direct clutch piston return springs from direct clutch piston.

NOTICE: When using compressed air to remove components, air pressure should not exceed 98 kPa (14 psi).





5. Direct clutch piston from direct clutch drum by temporarily installing the direct clutch assembly onto the fluid pump and applying low pressure compressed air into the direct clutch apply passage of the fluid pump.
6. Two direct clutch piston seals from direct clutch piston.

Clean
- All direct clutch components and dry thoroughly.

Inspect
1. Direct clutch discs for excessive wear or damage. Replace as necessary.
2. Direct piston for cracks or porosity. Replace as necessary.





3. Direct clutch piston check ball operation by applying compressed air into the working and release sides of the direct clutch piston. There must be no air leakage on the working side and air must pass freely through the release side. If these conditions do not exist, replace the direct clutch piston.
4. Direct clutch piston return spring for distortion or weakness. Replace as necessary.

Measure

- Tool Required:
- J 26900-6 Dial Caliper





- Inside diameter of the direct clutch bushing using a J 26900-6. Maximum inside diameter of the direct clutch bushing is 48.27 mm (1.9004 inch). If the inside diameter of the direct clutch bushing is greater than specified, replace the direct clutch drum.

NOTICE: When installing new clutch discs in the 1st-reverse brake, underdrive brake, underdrive clutch, intermediate brake, forward clutch or direct clutch assemblies, the new clutch discs MUST be soaked in Dexron-III Automatic Transmission Fluid GM P/N 12346143 or equivalent, two hours prior to installation. This causes the clutch material on the discs to permeate with fluid which will aid in ease of assembly and prevent clutch overheating on first time engagement.

INSTALL OR CONNECT

- Tools Required:
- J 36850 Transjel Transmission Assembly Lubricant
- J 23327 Clutch Spring Compressor





1. Two new direct clutch piston seals onto direct clutch piston.
2. Apply J 36850 to the new direct clutch piston seals.





3. Direct clutch piston into direct clutch drum with the cup side facing upwards.





4. Direct clutch piston return springs onto direct clutch piston.





5. Direct clutch piston return spring snap ring onto direct clutch piston return spring retainer using a J 23327 and a hydraulic press.





6. Three discs, three plates and direct clutch flange into direct clutch drum in the following order:
A. Plate
B. Disc
C. Plate
D. Disc
E. Plate
F. Disc
G. Flange

Important: The direct clutch flange must be installed with the flat side facing down and the stepped portion facing upwards.

7. Direct clutch snap ring into direct clutch drum.

Measure

- Tool Required:
- J 7872 Magnetic Base Indicator Set

- Direct clutch piston stroke after assembly using a J 7872. Temporarily install the direct clutch assembly onto the fluid pump and place the J 7872 plunger on the direct clutch piston. Apply 392 to 785 kPa (57 to 114 psi) of compressed air into the direct clutch apply passage of the fluid pump and observe the J 7872. Standard direct clutch piston stroke should fall within 1.12 to 1.52 mm (0.0441 to 0.0598 inch). If direct clutch piston stroke is greater or less than specified, and all direct clutch components exhibit little or no wear, select one of four different direct clutch flange sizes to bring direct clutch piston stroke within specification.
- Available direct clutch flange sizes:
- 2.60 mm (0.102 inch)
- 2.80 mm (0.110 inch)
- 3.00 mm (0.118 inch)
- 3.20 mm (0.126 inch)