Part 3

REAR CLUTCH-A-727

Disassembly






Figure 30 shows a disassembled view of the rear clutch assembly.
(1) Remove large selective snap ring that secures pressure plate in clutch retainer. Lift pressure plate, clutch plates, and inner pressure plate out of the retainer.
(2) Carefully pry one end of wave spring out of its groove in clutch retainer, then remove wave spring, spacer ring, and clutch piston spring.
(3) Invert clutch piston retainer assembly and bump it on a wood block to remove piston. Remove seals from the piston.
(4) If necessary, remove snap ring and press input shaft from clutch piston retainer.

Inspection

Inspect plates and discs for flatness. They must not be warped or cone shaped.
Inspect facing material on all driving discs. Replace discs that are charred, glazed or heavily pitted. Discs should also be replaced if they show evidence of material flaking off or if facing material can be scraped off easily. Inspect driving disc splines for wear or other damage. Inspect steel plate and pressure plate surfaces for burning, scoring or damaged driving lugs. Replace if necessary.
Inspect steel plate lug grooves in clutch retainer for smooth surfaces, plates must travel freely in the grooves. Note ball check in the piston, make sure ball moves freely. Inspect seal surfaces in clutch retainer for nicks or deep scratches, light scratches will not interfere with sealing of seals. Inspect seals for deterioration, wear, and hardness. Inspect piston spring, wave spring, and spacer for distortion or breakage.
Inspect interlocking seal rings (Fig. 30) on input shaft for wear or broken locks, make sure they turn freely in the grooves. Do not remove rings unless conditions warrant. Inspect bushing in input shaft for wear or scores. Inspect rear clutch to front clutch #2 thrust washer for wear. Washer thickness should be .061 to .063 inch, replace if necessary.

Input Shaft Bushing Replacement (A-727 only)

(1) Clamp input shaft in a vise with soft jaws, being careful not to clamp on seal ring lands or bearing journals.






(2) Assemble remover Tool SP-3630, cup Tool SP-3633, and hex nut Tool SP-1191 (Fig. 31).
(3) With cup held firmly against clutch piston retainer, thread remover into bushing as far as possible by hand.
(4) Using a wrench, screw remover into bushing 3 to 4 additional turns to firmly engage threads in the bushing.
(5) Turn hex nut down against cup to pull bushing from input shaft.
(6) Thoroughly clean input shaft to remove chips made by remover threads. Make certain small lubrication hole next to ball in end of shaft is not plugged with chips. Be sure no chips are lodged next to the steel ball.
(7) Slide a new bushing on installing head Tool SP-3636 and start them in the bore of input shaft.
(8) Stand input shaft upright on a clean smooth surface and install handle Tool SP-3549 or C-4171 in the installing head (Fig. 31). Drive bushing into shaft until tool bottoms.
(9) throughly clean input shaft and clutch piston retainer before assembly and installation.






Assembly

(1) If removed, press input shaft into clutch piston retainer and install snap ring.
(2) Lubricate and install inner and outer seals on clutch piston.






Make sure lip of seals face toward head of clutch retainer, and are properly seated in piston grooves (Fig. 30).
(3) Place piston assembly in retainer and, with a twisting motion, seat piston in bottom of the retainer.
(4) Position clutch retainer over piston retainer splines and support the assembly so clutch retainer remains in place.






(5) Place clutch piston spring and spacer ring on top of piston in clutch retainer, make sure spring and spacer ring are positioned in the retainer recess. Start one end of wave spring in retainer groove (Fig. 28), then progressively push or tap spring into place making sure it is fully seated in the groove.
(6) Install inner pressure plate in clutch retainer with raised portion of plate resting on the spring.
(7) Lubricate all clutch plates, install one lined disc followed by a steel plate until all plates are installed. Install outer pressure plate and selective snap ring.






(8) Measure rear clutch plate clearance by having an assistant press downward firmly on outer pressure plate, then insert a feeler gauge between the plate and snap ring (Fig. 29). See "Specifications" for allowed clearance. If necessary, install a new snap ring of proper thickness to obtain specified clearance. Low limit clearance is desirable. Rear clutch plate clearance is very important in obtaining proper clutch operation. The clearance can be adjusted by the use of various thickness outer snap rings. Snap rings are available in .060, .074, .088 and.106 inch thickness.
(9) Install #3 thrust washer on rear end of input shaft, using grease to hold in place.

PLANETARY GEAR TRAIN-A-904

End Play






Measure end play of planetary gear assemblies, sun gear and driving shell before removing these parts from output shaft. Stand assembly upright with forward end of output shaft on a wood block so that all parts will move forward against selective snap ring at front of shaft. Insert a feeler gauge between rear annulus gear support hub and shoulder on output shaft. (Fig. 32). The clearance should be .001 to.047 inch. If clearance exceeds specifications, replace thrust washers and/or necessary parts.

Disassembly (Fig. 33)






(1) Remove selective #3 thrust washer from forward end of output shaft.
(2) Remove selective snap ring from forward end of output shaft, then slide front planetary assembly off the shaft.
(3) Remove snap ring and #4 thrust washer from forward hub of front planetary gear assembly, slide front annulus gear and support off planetary gear set. Remove #5 thrust washer from front side of planetary gear set. Remove #6 thrust washer from rear side of planetary gear assembly. If necessary, remove snap ring from front of annulus gear to separate support from annulus gear.
(4) Slide sun gear, driving shell, and rear planetary assembly off the output shaft.
(5) Lift sun gear and driving shell off rear planetary assembly. Remove snap ring and #8 thrust plate from sun gear (rear side of driving shell). Slide sun gear out of driving shell, and remove snap ring (or spacer on 'wide ratio' transmissions) (Fig. 33) and #7 thrust plate from opposite end of sun gear if necessary.
(6) Remove #9 thrust washer from forward side of rear planetary assembly and remove planetary gear set from rear annulus gear. Remove #10 thrust washer from rear side of planetary assembly. If necessary, remove snap ring from rear of annulus gear to separate support from annulus gear.

Inspection

Inspect bearing surfaces on output shaft for nicks, burrs, scores or other damage. Light scratches, small nicks or burrs can be removed with crocus cloth or a fine stone. Inspect speedometer drive gear for any nicks or burrs, and remove with a sharp edged stone. Make sure all oil passages in shaft are open and clean.
Inspect bushings in sun gear for wear or scores, replace sun gear assembly if bushings are damaged. Inspect all thrust washers for wear and scores, replace if damaged or worn below specifications. Inspect thrust faces of planetary gear carriers for wear, scores or other damage, replace as required. Inspect planetary gear carrier for cracks and pinions for broken or worn gear teeth, and for broken pinion shaft lock pins. Inspect annulus gear and driving gear teeth for damage. Replace distorted lock rings.

Assembly






Refer to Figure 33 for parts reference.
(1) Place rear annulus gear support in annulus gear and install snap ring.
(2) Position #10 thrust washer on rear side of rear planetary gear assembly and install in rear annulus gear. Install #9 thrust washer on front side of rear planetary gear assembly.
(3) Insert output shaft in rear opening of rear annulus gear. Carefully work shaft through annulus gear support and planetary gear assembly. Make sure shaft splines are fully engaged in splines of annulus gear support.
(4) Install #7 thrust plate and snap ring (or spacer on 'wide ratio' transmissions) (Fig. 33) on one end of sun gear. Insert sun gear through front side of driving shell, install #8 thrust plate and snap ring.
(5) Carefully slide driving shell and sun gear assembly on the output shaft, engaging sun gear teeth with rear planetary pinion teeth.
(6) Place front annulus gear support in the annulus gear and install snap ring.
(7) Position #5 thrust washer on front side of front planetary gear assembly. Position front planetary gear assembly in front annulus gear, place #4 thrust washer over planetary gear assembly hub and install snap ring. Position #6 thrust washer on rear side of planetary gear assembly.
(8) Carefully work front planetary and annulus gear assembly on output shaft, meshing planetary pinions with sun gear teeth.
(9) With all components properly positioned, install selective snap ring on front end of output shaft. Remeasure end play of the assembly. The clearance can be adjusted by the use of various thickness snap rings. Snap rings are available in .042, 064 and .084 inch thickness.

PLANETARY GEAR TRAIN-A-727 (Fig. 34)






End Play

Measure end play of planetary gear assemblies, sun gear and driving shell before removing these parts from output shaft. Stand assembly upright with forward end of output shaft on a wood block so that all parts will move forward against selective snap ring at front of shaft. Insert a feeler gauge between rear annulus gear support hub and shoulder on output shaft (Fig. 32). The clearance should be .009 to .044 inch. If clearance exceeds specifications replace thrust washers and/or necessary parts.

Disassembly






(1) Remove #3 thrust plate from forward end of output shaft (Fig. 34).
(2) Remove selective snap ring from forward end of output shaft, then slide front planetary assembly off the shaft.
(3) Slide front annulus gear off planetary gear set. Remove #4 thrust washer from rear side of planetary gear set.
(4) Slide sun gear, driving shell, and rear planetary assembly off output shaft.
(5) Lift sun gear and driving shell off rear planetary gear assembly. Remove #5 thrust washer from inside the driving shell. Remove snap ring and #6 thrust plate from sun gear (rear side of driving shell) and slide sun gear out of the shell. Remove front snap ring from sun gear if necessary. Note that front end of sun gear is longer than rear.
(6) Remove #7 thrust washer from forward side of rear planetary gear assembly, remove planetary gear set and #8 thrust plate from rear annulus gear.

Inspection

Inspect bearing surfaces on output shaft for nicks, burrs, scores or other damage. Light scratches, small nicks or burrs can be removed with crocus cloth or a fine stone. Inspect speedometer drive gear for any nicks or burrs, and remove with a sharp edged stone. Make sure all oil passages in shaft are open and clean.
Inspect bushings in sun gear for wear or scores, replace sun gear assembly if bushings are damaged. Inspect all thrust washers for wear and scores, replace if damaged or worn below specifications. Inspect thrust faces of planetary gear carriers for wear, scores or other damage, replace as required. Inspect planetary gear carrier for cracks and pinions for broken or worn gear teeth and for broken pinion shaft lock pins. Inspect annulus gear and driving gear teeth for damage. Replace distorted lock rings.

Assembly






Refer to Figure 34 for parts identification.
(1) Install rear annulus gear on the output shaft. Apply a thin coat of grease on #8 thrust plate, place it on the shaft and in the annulus gear making sure teeth are over the shaft splines.
(2) Position rear planetary gear assembly in the rear annulus gear. Place #7 thrust washer on front side of planetary gear assembly.
(3) Install snap ring in front groove of sun gear (long end of gear). Insert sun gear through front side of driving shell, install rear #6thrust plate and snap ring.
(4) Carefully slide driving shell and sun gear assembly on output shaft, engaging sun gear teeth with rear planetary pinion teeth. Place #5 thrust washer inside the front driving shell.
(5) Place #4 thrust washer on rear hub of front planetary gear set, then slide assembly into front annulus gear.
(6) Carefully work front planetary and annulus gear assembly on output shaft, meshing planetary pinions with the sun gear teeth.
(7) With all components properly positioned, install selective snap ring on front end of output shaft. Remeasure end play of the assembly. The clearance can be adjusted by the use of various thickness snap rings. Snap rings are available in .048, .055 and .062 inch thickness.

OVERRUNNING CLUTCH

Inspection

Inspect clutch rollers for smooth round surfaces, they must be free of flat spots and chipped edges. Inspect roller contacting surfaces in the cam and race for brinelling. Inspect roller springs for distortion, wear or other damage.
A-727: Inspect cam set screw for tightness. If loose, tighten and restake the case around screw.

Overrunning Clutch Cam Replacement A-904






If overrunning clutch cam or spring retainer are found damaged, they can be replaced with a service replacement cam, spring retainer, and retaining bolts (Fig. 35). The service parts are retained in the case with bolts instead of rivets. To install, proceed as follows:
(1) Remove four bolts securing output shaft support to rear of the transmission case. Tap support rearward out of the case with a soft faced hammer.






(2) Center punch the rivets exactly in center of each rivet head (Fig. 36).
(3) Drill through each rivet head with a 3/8 inch drill. Be careful not to drill into the transmission case. Chip off rivet heads with a small chisel, then drive rivets and cam from the case with a blunt punch of proper size.
(4) Carefully enlarge rivet holes in the case with a 17/64 inch drill. Remove all chips and foreign matter from the case, make sure cam area is free of chips and burrs.






(5) To install, position cam and roller spring retainer in the case. Align cam bolt holes with holes in the case, then thread all seven retaining bolt and washer assemblies into cam a few turns. The cone washers must be installed so inner diameter is coned toward the bolt head (Fig. 37).
(6) Tap cam firmly into the case if necessary. Draw retaining bolts down evenly, then tighten to 100 in. lbs. (11 N.m).






(7) Screw two pilot studs, Tool C-3288-B into the case (Fig. 38). Position support over the pilot studs, and tap it firmly into the case with a soft faced hammer.
(8) Remove pilot studs, install bolts and tighten to 150 in. lbs. (17 N.m).

Overrunning Clutch Cam Replacement-A-727

If overrunning clutch cam and/or roller spring retainer are found damaged, replace cam and spring retainer in the following manner:
(1) Remove set screw from the case below clutch cam.
(2) Remove four bolts securing output shaft support to rear of transmission case.






Insert a punch through bolt holes and drive cam from the case (Fig. 39). Alternate punch from one bolt hole to another so cam will be driven evenly from the case. The output shaft support must be in the case to install the overrunning clutch cam. If the support requires replacement, tap support rearward with a soft faced hammer.






To install, screw two C-3288-B pilot studs into the case (Fig. 40). Position support over the pilot studs, and tap it firmly into the case with a soft faced hammer.
(3) Clean all burrs and chips from cam area in the case. fig. 40-lnstalling Output Shaft Support (A-727)
(4) Place spring retainer on the cam, making sure retainer lugs snap firmly into notches on the cam.
(5) Position cam in the case with cam serrations aligned with those in the case. Tap cam evenly into the case as far as possible with a soft faced hammer.






(6) Install Tool C-3863-A and Adapter SP-5124 as shown in Figure 41, tighten nut on tool to seat cam into the case. Make sure cam is firmly bottomed, then install cam retaining set screw. Stake the case around set screw to prevent it coming loose.






(7) Remove cam installing tool. Remove pilot studs, install bolts and tighten to 150 in. lbs. (17 N.m). Stake the case around cam in twelve places with a blunt chisel (Fig. 42).

KICKDOWN SERVO AND BAND

Disassembly

Disassemble controlled load servo piston by removing small snap ring from servo piston. Then remove washer, spring and piston rod assembly from servo piston.

Inspection

Inspect piston and guide seal rings for wear, and make sure they turn freely in the grooves. It is not necessary to remove seal rings unless conditions warrant. Inspect piston for cracks, burrs, scores and wear. Inspect piston bore in the case for scores or other damage. Inspect fit of guide on piston rod. Inspect piston spring for distortion.
For controlled load servo, inspect bore in piston and "0" ring on piston rod.
Inspect band lining for wear and bond of lining to the band. Inspect lining for black burn marks, glazing, nonuniform wear pattern and flaking. If lining is worn so grooves are not visible at ends or any portion of the bands, replace the band. Inspect band for distortion or cracked ends

Assembly






Assemble controlled load servo piston as follows (Fig. 43).
(1) Grease "0" ring and install on piston rod.
(2) Install piston rod into servo piston.
(3) Install spring, flat washer and snap ring to complete the assembly ends.

LOW-REVERSE SERVO AND BAND

Disassembly






(1) Remove snap ring from piston and remove the piston plug and spring (Fig. 44).

Inspection

Inspect seal for deterioration, wear and hardness. Inspect piston and piston plug for cracks, burrs, scores and wear; piston plug must operate freely in the piston. Inspect piston bore in the case for scores or other damage. Inspect springs for distortion.
Inspect band lining for wear and bond of lining to the band. If lining is worn so grooves are not visible at ends or any portion of the band, replace the band. Inspect band for distortion or cracked ends.

Assembly

(1) Lubricate and insert piston plug and spring in the piston, and secure with snap ring.