For 1990-2009 cars

#### Tools Required

• | J 41681 Clutch Spring Compressor

• | J 8001 Dial Indicator Set

• | J 26900-13 Magnetic Base

• | J 36850 Transjel® Transmission Assembly Lubricant

### Removal and Inspection Procedure

1. Remove the following components from the input shaft assembly.

• | The snap ring (1)

• | The direct clutch input hub (2)

• | The forward clutch hub (3)

2. Remove the following components from the input shaft:

• | The thrust bearing No. 2 race (1)

• | The thrust rear bearing race (3)

• | The forward clutch thrust bearing (2)

3. Temporarily install the direct clutch input hub (1) and the snap ring (2) into the forward clutch.
4. Temporarily install the forward clutch (1) into the overdrive case (2).
5. Measure the forward clutch piston stroke using J 8001 and J 26900-13 :

5.1. | Place the J 8001 plunger on the forward clutch piston.

5.2. | Apply 392-785 kPa (57-114 psi) of compressed air into the fluid passage at the right of the cut in the overdrive case.

5.3. | Take the measurement.

Specification
Forward clutch piston stroke (standard): 1.40-2.24 mm (0.056-0.088 in)

5.4. | If the forward clutch piston stroke is not within specifications, install a 1.80-mm or 2.00-mm (0.071-in or 0.079-in) clutch disc in order to adjust.

6. Remove the forward clutch from the overdrive case.
7. Remove the direct clutch input hub and snap ring from the forward clutch hub.
8. Remove the following forward clutch hub components:

• | The snap ring (1)

• | The clutch plates

• | The discs

9. Compress the forward clutch piston return springs using the J 41681 and a press while removing the snap ring.
10. Remove the forward clutch piston return springs.
11. Install the forward clutch (1) to the overdrive case.
12. Apply low compressed air pressure to the fluid passage at the right of the overdrive case in order to remove the forward clutch piston.
13. Remove the forward clutch piston O-rings.
14. Measure the free length of the forward clutch piston return springs.

Specification
Forward clutch piston return spring free length (standard): 15.10 mm (0.0594 in)

Replace if not within specifications.

15. Clean all forward clutch components.
16. Allow the components to air dry.
17. Inspect the forward clutch disc for excessive wear or damage. Replace as necessary.
18. Inspect the forward clutch piston for cracks or porosity. Replace as needed.
19. Shake the piston in order to inspect the forward clutch piston check ball free movement.
20. Apply low compressed air pressure to the check ball opening in order to inspect for leaks. Repair or replace as necessary.

### Installation Procedure

1. Install a new O-ring to the forward clutch piston.
2. Lubricate the O-ring with A/T fluid.
3. Install the piston to the forward clutch drum.
4. Install the piston return springs.
5. Install the spring retaining plate.
6. Compress the forward clutch piston return springs using J 41681 while installing the snap ring (1).
7. Install the forward clutch discs and plates 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 plate

7.8. | The disc

8. Install the forward clutch snap ring.
9. Install the following components, lubricating with J 36850 :

• | The forward clutch thrust bearing

• | The thrust rear bearing race

• | The thrust bearing No. 2 race

10. Install the forward clutch hub (3).
11. Install the direct clutch hub (2).
12. Install the snap ring.