For 1990-2009 cars

### Measurement Procedure

#### Tools Required

• | J 8001 Dial Indicator Set

• | J 26900-13 Magnetic Base

Perform the following procedure before disassembling the direct clutch:

1. Install the J 8001 and the J 26900-13 .
2. Temporarily install the direct clutch (1) onto the center support (2).
3. Place the J 8001 plunger on the direct clutch piston.
4. Apply 392-785 kPa (57-114 psi) of compressed air into the second LH fluid passage in the overdrive case.
5. Measure the direct clutch piston stroke.

Specification
Direct clutch piston stroke (standard): 0.19-1.75 mm (0.008-0.068 in)

6. If the direct clutch piston stroke is not within specifications, install a flange of one of the following sizes in order to adjust the stroke:

• | 3.60 mm (0.141 in)

• | 3.80 mm (0.149 in)

• | 4.00 mm (0.157 in)

### Removal and Inspection Procedure

#### Tools Required

J 41681 Clutch Spring Compressor

1. Remove the direct clutch from the center support.
2. Remove the direct clutch snap ring from the direct clutch drum.
3. Remove the following components from the direct clutch drum:

• | The flange (1)

• | The discs (3)

• | The plates (2)

4. Remove the direct clutch piston return spring snap ring (1) from the direct clutch piston retainer using the J 41681 and a press.
5. Remove the direct clutch piston return springs from the direct clutch piston.

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

6. Remove the direct clutch piston from the direct clutch drum:

• | Temporarily install the drum onto the center support (2).

• | Apply low pressure compressed air into the second LH fluid passage.

7. Apply low pressure compressed air into the extreme RH fluid passage in order to remove the direct clutch inner piston.
8. Remove the inner and outer direct clutch piston O-rings.
9. Measure the direct clutch piston return springs:

Specification
Direct clutch piston return spring free length (standard): 15.13 mm (0.059 in)

Replace as necessary.

10. Clean all direct clutch components.
11. Allow the components to air dry.
12. Inspect the direct clutch disc for excessive wear or damage. Replace as necessary.
13. Inspect the direct clutch pistons for cracks or porosity. Replace as necessary.
14. Shake the piston in order to inspect the free movement of the check ball.
15. Apply low pressure compressed air to the check ball opening (2) in order to inspect for leaks.

### Installation Procedure

#### Tools Required

• | J 41681 Clutch Spring Compressor

• | J 36850 Transjel® Transmission Assembly Lubricant

1. Install new O-rings to the direct clutch inner and outer pistons.
2. Lubricate the O-rings with A/T fluid.
3. Install the direct clutch inner piston.
4. Install the direct clutch outer piston.

Important: When installing the return springs, do not allow the springs to tilt or fall out of place.

5. Install the direct clutch piston return springs into the direct clutch piston.

Important: Do not align the snap ring opening with the cutout in the direct clutch drum during the next step.

6. Install the direct clutch piston return spring snap ring onto the spring retainer using the J 41681 and a press.
7. Install the direct clutch plates and discs in the following order:

7.1. | The plate

7.2. | The disc

7.3. | The plate

7.4. | The disc

7.5. | The plate

7.6. | The disc

7.7. | The flange

8. Install the direct clutch flange with the flat side facing down and the stepped portion facing upwards.
9. Install the direct clutch snap ring into the direct clutch drum.
10. Install the following components in the order listed:

10.1. | The race

10.2. | The thrust bearing and race

11. Lubricate the races and bearing with lubricate J 36850 .