17-21. DIRECT CLUTCH ASSEMBLY REPAIR (4L80-E) (Cont'd)
All transmission parts must be lubricated with clean transmission
fluid (Dexron III) before assembly. Foreign material will cause
For general assembly instructions, refer to para 2-16.
Perform step 1 for 1995-1996 transmissions only.
With piston (2) facing up, install inner seal (3), outer seal (4), lip side down, and direct clutch
seal (5), lip side up, into clutch housing (6).
Position seal protectors J38732-1 and J21362-1 on direct clutch housing (6).
Perform step 2.1 for 1995-1996 transmissions only.
Install piston (2) using twisting motion until seated.
Using spring compressor and adapter, install spring and retainer assembly (1) on piston (2) with
Install sprag assembly (11) over rear hub of direct clutch housing (6).
Install outer race (10), groove side up, and clutch retainer (9) over sprag assembly (11) with
Check sprag assembly (11) to ensure it only turns clockwise and locks on housing (6) when turned
Install dished plate (15) (1995-1996 transmission only), cupped surface toward piston (2), on direct
clutch housing (6).
Install five clutch plates (16) and clutch plate assemblies (14) on clutch housing (6). Alternate
plates, starting with a clutch plate (16).
Install backing plate (13) on housing (6) with snapring (12).
e. Direct Clutch Piston Movement Measurement
Set direct clutch assembly (17) on center support (18).
Set dial indicator to seat on direct clutch assembly (17).
Air pressure must not exceed 80 psi (552 kPa) when air checking
Apply 80 psi (552 kPa) of air pressure to direct clutch fluid passage (20) in center support (18) only.
Do not apply air pressure to reverse passage (19), air will vent out normally.
Piston should move to compress clutch plates. Travel should be 0.121-0.186 in. (3.07-4.72 mm).
If correct measurement is read, remove direct clutch assembly (17) from center support (18).
If incorrect measurement is read, check clutch plates (16) and (14) for proper installation. Replace
all clutch plates if damaged.