3RD Clutch & Reaction Carrier
3RD CLUTCH & REACTION CARRIER 4T80-E TRANSAXLEDISASSEMBLE
1. Remove thrust bearing and selective thrust washer from 3rd clutch housing.
2. Remove snap ring, input sun gear and thrust bearing.
3. Remove reaction carrier assembly. Thrust bearing will remain in reaction carrier.
4. Remove reaction sun gear and carrier assembly, then thrust washer, snap ring, apply plate and clutch plates.
5. Compress spring assembly using clutch compressor tool No. J-39694, or equivalent.
6. Remove snap ring retainer.
7. Remove spring and retainer assembly, then piston assembly.
INSPECTION
1. Inspect 3rd clutch housing for plugged feed holes.
2. Inspect snap rings for overexpansion.
3. Inspect sun gears and thrust bearings for damage or wear.
4. Using a feeler gauge, inspect planet pinions for wear or damage. Specification is 0.09-0.90 mm.
5. Inspect reaction sun gear and shell assembly and hub and bushing assembly for scoring, nicks or scratches.
6. Inspect steel clutch plates for scoring. Replace fiber plates.
7. Inspect piston assembly seals for rollover or tearing. Replace piston and seal assembly if seals are damaged.
8. Inspect piston assembly checkball orifices for damage caused by check ball peening. Check balls should move freely in capsule.
9. Inspect spring and retainer assembly for missing or broken springs
ASSEMBLE
1. If input seal rings need replacement, proceed as follows:
a. Cut oil seal rings and remove from input shaft.
b. Inspect seal ring grooves for nicks or burrs.
c. Inspect input shaft for cracks or blocked fluid passages.
d. Inspect input shaft bushing for excessive wear.
e. Adjust adjustable seal protector tool No. J-34741-1A, or equivalent, so bottom of seal installer matches correct seal groove.
f. Lubricate oil seal ring with transaxle fluid and position it on adjustable seal protector tool No. J-34741-1A, or equivalent.
g. Use seal pusher tool No. J-34741-2, or equivalent, to quickly slide seal into seal ring groove.
h. Repeat preceding step for remaining oil seal ring.
i. Slide seal sizer tool No. J-34741-3, or equivalent, over seals with a twisting motion to size seals. Leave in place until input housing is ready to be installed. Sizer must contact 3rd clutch housing hub.
2. Lubricate all 2nd, 3rd forward/coast and reverse piston assemblies with a light coat of Transjel part No. J-36850, or equivalent, when installing piston assemblies.
3. Install piston assemblies into bottom (larger clutch basket) side of 3rd clutch housing. Lubricate seals with light coat of Transjel part No. J-36850, or equivalent. Use a twisting motion when pushing piston into housing.
4. Install spring and retainer assembly, then snap ring retainer.
5. Compress spring and retainer assembly using clutch compressor tool No. J-39694, or equivalent.
6. Install snap ring, then remove clutch compressor tool.
7. Install apply plate, then clutch plates. Start with fiber plate and alternate from fiber to steel. Install backing plates stepped side up.
8. Install snap ring and thrust washer, then 3rd clutch hub and bushing assembly.
9. Install thrust bearing, rolled inner lip facing toward clutch pack.
10. Install reaction sun gear and shell assembly.
11. Install thrust bearing inside reaction carrier if it was removed, then reaction carrier assembly.
12. Install thrust bearing, black surface toward clutch pack.
13. Install input sun gear. Sun gear can be installed in either direction.
14. Install snap ring, then selective thrust washer and thrust bearing to top of clutch housing with Transjel part No. J-36850, or equivalent.