D. Forward Clutch Assembly

Measure

- Tool Required:
- J 7872 Magnetic Base Indicator Set








- Forward clutch piston stroke before disassembly using a J 7872. Temporarily install the direct clutch assembly onto the fluid pump and the forward clutch assembly into the direct clutch assembly. Place the J 7872 plunger on the forward clutch piston and apply 392 to 785 kPa (57 to 114 psi) of compressed air into the forward clutch apply passage on the fluid pump. Standard forward clutch piston stroke should fall within 1.42 to 1.81 mm (0.0559 to 0.0713 inch). If a correct reading cannot be obtained, remove the forward clutch assembly from the direct clutch assembly and apply 392 to 785 kPa (57 to 114 psi) of compressed air into the forward clutch apply passage on the input shaft and observe the J 7872. If forward clutch piston stroke is greater or less than specified, inspect all direct clutch components for excessive wear.

REMOVE OR DISCONNECT

- Tools Required:
- J 23327 Clutch Spring Compressor





1. Three input shaft seal rings from input shaft.





2. Forward clutch snap ring from forward clutch drum.





3. Forward clutch flange, four discs and four plates from forward clutch drum.





4. Forward clutch piston return spring snap ring from forward clutch piston return spring retainer using a J 23327 and a hydraulic press.
5. Forward clutch piston return spring from forward clutch piston.

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





6. Forward clutch piston from forward clutch drum by applying low pressure compressed air into the forward clutch apply passage on the input shaft.
7. Two forward clutch piston seals from forward clutch piston.

Clean
- All forward clutch components and dry thoroughly.

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





3. Forward clutch piston check ball operation by applying compressed air into the working and release sides of the forward 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 forward clutch piston.
4. Forward clutch piston return spring for distortion or weakness. Replace as necessary.

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 forward clutch piston seals onto forward clutch piston.
2. Apply J 36850 to the new forward clutch piston seals.





3. Forward clutch piston into forward clutch drum with the cup side facing upwards.
4. Forward clutch piston return spring onto forward clutch piston.





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





6. Four discs, four plates and forward clutch flange into forward clutch drum in the following order:
A. Plate
B. Disc
C. Plate
D. Disc
E. Plate
F. Disc
G. Plate
H. Disc
I. Flange

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

7. Forward clutch snap ring into direct clutch drum.
8. Three new input shaft seal rings onto input shaft.
9. Apply J 36850 to the new input shaft seal rings.

Measure

- Tool Required:
- J 7872 Magnetic Base indicator Set

- Forward clutch piston stroke after assembly using a J 7872. Place the J 7872 plunger on the forward clutch piston and apply 392 to 785 kPa (57 to 114 psi) of compressed air into the forward clutch apply passage on the input shaft and observe the J 7872. Standard forward clutch piston stroke should fall within 1.42 to 1.81 mm (0.0559 to 0.0713 inch). If forward clutch piston stroke is greater or less than specified, and all forward clutch components exhibit little or no wear, select one of five different forward clutch flange sizes to bring forward clutch piston stroke within specification.
- Available forward clutch flange sizes:
- 2.80 mm (0.110 inch)
- 3.00 mm (0.118 inch)
- 3.20 mm (0.126 inch)
- 3.37 mm (0.1327 inch)
- 3.60 mm (0.1417 inch)