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tion shaft housing should be 0.010 to 0.063 mm (0.0004 to 0.0025 in.). Both clearances can be mea- sured at the same time by installing the gears in the pump body and measure pump component clearances as follows:
(1) Position an appropriate piece of Plastigage™
across both gears.
tion shaft housing.
(2) Align the plastigage to a flat area on the reac-
(3) Install the reaction shaft to the pump housing. (4) Separate the reaction shaft housing from the pump housing and measure the Plastigage™ follow- ing the instructions supplied with it.
AUTOMATIC TRANSMISSION - 46RE
21 - 215
DR OIL PUMP (Continued)
Clearance between inner gear tooth and outer gear should be 0.08 to 0.19 mm (0.0035 to 0.0075 in.). Measure clearance with an appropriate feeler gauge (Fig. 125).
Clearance between outer gear and pump housing should be 0.10 to 0.19 mm (0.004 to 0.0075 in.). Mea- sure clearance with an appropriate feeler gauge.
Fig.125CheckingPumpGearTipClearance
1 - FEELER GAUGE 2 - INNER GEAR 3 - OUTER GEAR
ASSEMBLY
OIL PUMP BUSHING
Fig.126OilPumpBushing
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL SP-3550
3 - BUSHING 4 - SPECIAL TOOL SP-5118
5 - SPECIAL TOOL C-4171
6 - PUMP HOUSING(1) Assemble Tool Handle C-4171 and Bushing
Installer SP-5118 (Fig. 126).
(2) Place bushing on installer tool and start bush-
ing into shaft.
(3) Tap bushing into place until Installer Tool SP-5118 bottoms in pump cavity. Keep tool and bush- ing square with bore. Do not allow bushing to become cocked during installation.
(4) Stake pump bushing in two places with blunt punch. Remove burrs from stake points with knife blade (Fig. 127).
Fig.127Staking-DeburringOilPumpBushing
1 - TWO STAKES 2 - NARROW BLADE 3 - BLUNT PUNCH
AUTOMATIC TRANSMISSION - 46RE
21 - 216
OIL PUMP (Continued) REACTION SHAFT SUPPORT BUSHING(1) Place reaction shaft support upright on a clean,
smooth surface.
(2) Assemble Bushing Installer Tools C-4171 and SP-5302. Then slide new bushing onto installer tool (Fig. 128).
(3) Start bushing in shaft. Tap bushing into shaft
until installer tool bottoms against support flange.
(4) Clean reaction shaft support thoroughly after
bushing replacement (to remove any chips).
DR
CAUTION: The reaction shaft support seal rings will break if overspread, or twisted. If new rings are being installed, spread them only enough for instal- lation. Also be very sure the ring ends are securely hooked together after installation. Otherwise, the rings will either prevent pump installation, or break during installation.
(4) Align and install reaction shaft support on
pump body.
(5) Install bolts attaching reaction shaft support to pump. Tighten bolts to 20 N·m (175 in. lbs.) torque. (6) Install new pump seal with Installer Tool C-3860-A (Fig. 129). Use hammer or mallet to tap seal into place.
(7) Install new o-ring on pump body. Lubricate oil
seal and o-ring with petroleum jelly.
(8) Cover pump assembly to prevent dust entry
and set aside for assembly installation.
Fig.128ReactionShaftBushing
1 - SPECIAL TOOL SP-1191
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL SP-3633
4 - SPECIAL TOOL SP-5301
5 - SPECIAL TOOL SP-5302
6 - BUSHING 7 - REACTION SHAFT 8 - BUSHINGOIL PUMP BODY
Fig.129OilPumpSeal
1 - SPECIAL TOOL C-3860-A 2 - PUMP BODY 3 - PUMP SEAL
(1) Lubricate pump gears with transmission fluid
and install them in pump body.
(2) Install thrust washer on reaction shaft support hub. Lubricate washer with petroleum jelly or trans- mission fluid before installation.
(3) If reaction shaft seal rings are being replaced, install new seal rings on support hub. Lubricate seal rings with transmission fluid or petroleum jelly after installation. Squeeze each ring until ring ends are securely hooked together.
DR
AUTOMATIC TRANSMISSION - 46RE
21 - 217
OUTPUT SHAFT FRONT BEARING REMOVAL
OUTPUT SHAFT REAR BEARING REMOVAL
(1) Remove overdrive unit from the vehicle. (2) Remove overdrive geartrain from housing. (3) Remove snap-ring holding output shaft front
bearing to overdrive geartrain. (Fig. 130).
(4) Pull bearing from output shaft.
Fig.130OutputShaftFrontBearing
1 - OUTPUT SHAFT FRONT BEARING 2 - SNAP-RING 3 - OUTPUT SHAFT 4 - GROOVE TO REAR 5 - OVERDRIVE GEARTRAIN
INSTALLATION
(1) Place replacement bearing in position on geartrain with locating retainer groove toward the rear.
(2) Push bearing onto shaft until the snap-ring
(3) Install snap-ring to hold bearing onto output
groove is visible.
shaft.
(1) Remove overdrive unit from the vehicle. (Refer to 21 - TRANSMISSION/AUTOMATIC/OVERDRIVE - REMOVAL)
(2) Remove overdrive geartrain from housing. (3) Remove snap-ring holding output shaft rear
bearing into overdrive housing (Fig. 131).
(4) Using a suitable driver inserted through the
rear end of housing, drive bearing from housing.
Fig.131OutputShaftRearBearing
1 - OUTPUT SHAFT REAR BEARING 2 - OVERDRIVE HOUSING 3 - SNAP-RING
INSTALLATION
(1) Place replacement bearing in position in hous-
ing.
(2) Using a suitable driver, drive bearing into
housing until the snap-ring groove is visible.
(3) Install snap-ring to hold bearing into housing
(4) Install overdrive geartrain into housing. (5) Install overdrive unit in vehicle.
(4) Install overdrive geartrain into housing. (5) Install overdrive unit in vehicle.
(Fig. 131).
21 - 218
AUTOMATIC TRANSMISSION - 46RE
DR
OVERDRIVE CLUTCH DESCRIPTION
The overdrive clutch (Fig. 132) is composed of the pressure plate, clutch plates, holding discs, overdrive piston retainer, piston, piston spacer, and snap-rings. The overdrive clutch is the forwardmost component in the transmission overdrive unit and is considered a holding component. The overdrive piston retainer, piston, and piston spacer are located on the rear of the main transmission case.
NOTE: The number of discs and plates may vary with each engine and vehicle combination.
OPERATION
To apply the clutch, pressure is applied between the piston retainer and piston. The fluid pressure is pro- vided by the oil pump, transferred through the control valves and passageways, and enters the clutch through passages at the lower rear portion of the valve body area. With pressure applied between the piston retainer and piston, the piston moves away from the piston retainer and compresses the clutch pack. This action applies the clutch pack, allowing torque to flow through the intermediate shaft into the overdrive planetary gear set. The overdrive clutch discs are attached to the over- drive clutch hub while the overdrive clutch plates, reac- tion plate, and pressure plate are lugged to the overdrive housing. This allows the intermediate shaft to
transfer the engine torque to the planetary gear and overrunning clutch. This drives the planetary gear inside the annulus, which is attached to the overdrive clutch drum and output shaft, creating the desired gear ratio. The waved snap-ring is used to cushion the appli- cation of the clutch pack.
OVERDRIVE SWITCH DESCRIPTION
The overdrive OFF (control) switch is located in the shift lever arm (Fig. 133). The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function.
OPERATION
At key-on, overdrive operation is allowed. Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off. The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the con- trol switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4
upshift. The control switch indicator light illuminates only when the overdrive switch is turned to the OFF position, or when illuminated by the transmission control module.1 - REACTION PLATE
Fig.132OverdriveClutch
2 - PRESSURE PLATE
DR OVERDRIVE SWITCH (Continued)
AUTOMATIC TRANSMISSION - 46RE
21 - 219
Fig.133OverdriveOffSwitch
DIAGNOSIS AND TESTING - OVERDRIVE ELECTRICAL CONTROLS
The overdrive off switch, valve body solenoid, case connectors and related wiring can all be tested with a 12 volt test lamp or a volt/ohmmeter. Check conti- nuity of each component when diagnosis indicates this is necessary.
Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range.
REMOVAL
(1) Using a plastic trim tool, remove the overdrive
off switch retainer from the shift lever (Fig. 134).
Fig.135RemovetheOverdriveOffSwitch
1 - GEAR SHIFT LEVER 2 - OVERDRIVE OFF SWITCH
INSTALLATION
NOTE: There is enough slack in the wire to pull out the connector from the lever.
(1) Pull the connector out of the lever just enough
to grasp it.
CAUTION: Be careful not to bend the pins on the overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly.
(2) Install the overdrive off switch into the connec-
tor (Fig. 136)
Fig.134OverdriveOffSwitchRetainer
1 - GEAR SHIFT LEVER 2 - OVERDRIVE OFF SWITCH RETAINER 3 - PLASTIC TRIM TOOL
(2) Pull the switch outwards to release it from the
connector in the lever (Fig. 135)
Fig.136InstalltheOverdriveOffSwitch
1 - GEAR SHIFT LEVER 2 - OVERDRIVE OFF SWITCH WIRING CONNECTOR 3 - OVERDRIVE OFF SWITCH
(3) Push the overdrive off switch and wiring into
(4) Install the overdrive off switch retainer onto
the shift lever.
the shift lever.
21 - 220
AUTOMATIC TRANSMISSION - 46RE
DR
OVERDRIVE UNIT REMOVAL
(1) Shift transmission into PARK. (2) Raise vehicle. (3) Remove transfer case, if equipped. (4) Mark propeller shaft universal joint(s) and axle pinion yoke, or the companion flange and flange yoke, for alignment reference at installation, if neces- sary.
(5) Disconnect and remove the rear propeller shaft, if necessary. (Refer to 3 - DIFFERENTIAL & DRIV- ELINE/PROPELLER SHAFT/PROPELLER SHAFT - REMOVAL)
(6) Remove transmission oil pan, remove gasket,
drain oil and reinstall pan.
(7) If overdrive unit had malfunctioned, or if fluid is contaminated, remove entire transmission. If diag- nosis indicated overdrive problems only, remove just the overdrive unit.
(8) Support transmission with transmission jack. (9) Remove bolts attaching overdrive unit to trans-
mission (Fig. 137).
CAUTION: Support the overdrive unit with a jack before moving it rearward. This is necessary to pre- vent damaging the intermediate shaft. Do not allow the shaft to support the entire weight of the over- drive unit.
(10) Carefully work overdrive unit off intermediate shaft. Do not tilt unit during removal. Keep it as level as possible.
(11) If overdrive unit does not require service, immediately insert Alignment Tool 6227-2 in splines of planetary gear and overrunning clutch to prevent splines from rotating out of alignment. If misalign- ment occurs, overdrive unit will have to be disassem- bled in order to realign splines.
(12) Remove and retain overdrive piston thrust bearing. Bearing may remain on piston or in clutch hub during removal.
(13) Position drain pan on workbench. (14) Place overdrive unit over drain pan. Tilt unit
to drain residual fluid from case.
(15) Examine fluid for clutch material or metal fragments. If fluid contains these items, overhaul will be necessary.
(16) If overdrive unit does not require any service, leave alignment tool in position. Tool will prevent accidental misalignment of planetary gear and over- running clutch splines.
DISASSEMBLY
(1) Remove transmission speed sensor and o-ring
seal from overdrive case (Fig. 138).
(2) Remove overdrive piston thrust bearing (Fig.
139).
Fig.137OverdriveUnitBolts
1 - OVERDRIVE UNIT 2 - ATTACHING BOLTS (7)
Fig.138TransmissionSpeedSensor
1 - SOCKET AND WRENCH 2 - SPEED SENSOR 3 - O-RING
DR OVERDRIVE UNIT (Continued)
AUTOMATIC TRANSMISSION - 46RE
21 - 221
(2) Remove intermediate shaft spacer (Fig. 141). Retain spacer. It is a select fit part and may possibly be reused.
Fig.139OverdrivePistonThrustBearingRemoval/
Installation
1 - THRUST BEARING 2 - OVERDRIVE PISTON 3 - THRUST PLATE
OVERDRIVE PISTON
(1) Remove overdrive piston thrust plate (Fig. 140). Retain thrust plate. It is a select fit part and may possibly be reused.
Fig.141IntermediateShaftSpacerLocation
1 - INTERMEDIATE SHAFT 2 - INTERMEDIATE SHAFT SPACER (SELECT FIT)
(3) Remove overdrive piston from retainer (Fig.
142).
Fig.140OverdrivePistonThrustPlateRemoval/
Installation
1 - OVERDRIVE PISTON 2 - OVERDRIVE PISTON SPACER (SELECT FIT)
Fig.142OverdrivePistonRemoval
1 - PISTON RETAINER 2 - OVERDRIVE PISTON
AUTOMATIC TRANSMISSION - 46RE
21 - 222
OVERDRIVE UNIT (Continued) OVERDRIVE CLUTCH PACKDR
(1) Remove overdrive clutch pack wire retaining
ring (Fig. 143).
(2) Remove overdrive clutch pack (Fig. 144). (3) Note position of clutch pack components for
assembly reference (Fig. 145).
Fig.143RemovingOverdriveClutchPackRetaining
Ring
1 - OVERDRIVE CLUTCH PACK RETAINING RING
Fig.144OverdriveClutchPackRemoval
1 - OVERDRIVE CLUTCH PACK
OVERDRIVE GEARTRAIN
(1) Remove overdrive clutch wave spring (Fig.
146).
(2) Remove overdrive clutch reaction snap-ring (Fig. 147). Note that snap-ring is located in same groove as wave spring.
Fig.145OverdriveClutchComponentPosition-
Typical
1 - REACTION PLATE 2 - CLUTCH PLATES (3)
3 - PRESSURE PLATE 4 - CLUTCH DISCS (4)
Fig.146OverdriveClutchWaveSpringRemoval
1 - WAVE SPRING
Fig.147OverdriveClutchReactionSnap-Ring
Removal
1 - REACTION RING 2 - CLUTCH HUB
DR OVERDRIVE UNIT (Continued)
(3) Remove Torx™ head screws that attach access
cover and gasket to overdrive case (Fig. 148).
(4) Remove access cover and gasket (Fig. 149).
AUTOMATIC TRANSMISSION - 46RE
21 - 223
(6) Lift gear case up and off geartrain assembly
(Fig. 151).
Fig.148AccessCoverScrewRemoval
1 - TORX SCREWDRIVER (T25) 2 - ACCESS COVER SCREWS
Fig.151RemovingGeartrain
1 - GEARTRAIN ASSEMBLY 2 - GEAR CASE
(7) Remove snap-ring that retains rear bearing on
(8) Remove rear bearing from output shaft (Fig.
output shaft.
152).
Fig.149AccessCoverAndGasketRemoval
1 - ACCESS COVER AND GASKET
(5) Expand output shaft bearing snap-ring with expanding-type snap-ring pliers. Then push output shaft forward to release shaft bearing from locating ring (Fig. 150).
Fig.150ReleasingBearingFromLocatingRing
1 - EXPAND BEARING LOCATING RING WITH SNAP-RING PLIERS 2 - ACCESS HOLE
Fig.152RearBearingRemoval
1 - OUTPUT SHAFT 2 - REAR BEARING 3 - SNAP-RING
DR
(4) Remove direct clutch pack snap-ring (Fig. 154). (5) Remove direct clutch hub retaining ring (Fig. 155).
AUTOMATIC TRANSMISSION - 46RE
21 - 224
OVERDRIVE UNIT (Continued) DIRECT CLUTCH, HUB AND SPRINGWARNING: THE NEXT STEP IN DISASSEMBLY INVOLVES COMPRESSING THE DIRECT CLUTCH SPRING. IT IS EXTREMELY IMPORTANT THAT PROPER EQUIPMENT BE USED TO COMPRESS THE SPRING AS SPRING FORCE IS APPROXIMATELY 830 POUNDS. USE SPRING COMPRESSOR TOOL 6227-1 AND A HYDRAU- LIC SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 5-6 INCHES. THE PRESS MUST ALSO HAVE A BED THAT CAN BE ADJUSTED UP OR DOWN AS REQUIRED. RELEASE CLUTCH SPRING TENSION SLOWLY AND COMPLETELY TO AVOID PERSONAL INJURY.
(1) Mount geartrain assembly in shop press (Fig. 153). (2) Position Compressor Tool 6227-1 on clutch hub (Fig. 153). Support output shaft flange with steel press plates as shown and center assembly under press ram.
(3) Apply press pressure slowly. Compress hub and spring far enough to expose clutch hub retaining ring and relieve spring pressure on clutch pack snap-ring (Fig. 153).
Fig.154DirectClutchPackSnap-RingRemoval
1 - CLUTCH HUB 2 - SPECIAL TOOL 6227-1
3 - DIRECT CLUTCH PACK SNAP-RING 4 - PRESS PLATES 5 - CLUTCH DRUMFig.153GeartrainMountedInShopPress
1 - PRESS RAM 2 - SPECIAL TOOL C-3995-A (OR SIMILAR TOOL) 3 - CLUTCH HUB 4 - PLATES 5 - PRESS BED 6 - SPECIAL TOOL 6227-1
Fig.155DirectClutchHubRetainingRingRemoval 1 - SPECIAL TOOL 6227-1
2 - CLUTCH HUB RETAINING RING 3 - PRESS BED 4 - PRESS PLATESDR OVERDRIVE UNIT (Continued)
AUTOMATIC TRANSMISSION - 46RE
21 - 225
(6) Release press load slowly and completely (Fig.
156).
(7) Remove Special Tool 6227-1. Then remove
clutch pack from hub (Fig. 156).
Fig.158RemovingSunGear,ThrustBearingAnd
PlanetaryGear
1 - PLANETARY GEAR 2 - PLANETARY THRUST BEARING 3 - CLUTCH SPRING PLATE 4 - SPRING PLATE SNAP-RING 5 - SUN GEAR
(3) Remove overrunning clutch assembly with expanding type snap-ring pliers (Fig. 159). Insert pli- ers into clutch hub. Expand pliers to grip hub splines and remove clutch with counterclockwise, twisting motion.
Fig.156DirectClutchPackRemoval
1 - SPECIAL TOOL 6227-1
2 - DIRECT CLUTCH HUB 3 - DIRECT CLUTCH PACKGEARTRAIN
(1) Remove direct clutch hub and spring (Fig. 157). (2) Remove sun gear and spring plate. Then remove planetary thrust bearing and planetary gear (Fig. 158).
Fig.159OverrunningClutchAssemblyRemoval/
Installation
1 - OVERRUNNING CLUTCH 2 - NEEDLE BEARING
Fig.157DirectClutchHubAndSpringRemoval
1 - DIRECT CLUTCH SPRING 2 - DIRECT CLUTCH HUB
21 - 226
OVERDRIVE UNIT (Continued)AUTOMATIC TRANSMISSION - 46RE
DR
(4) Remove
thrust
bearing
from overrunning
clutch hub.
(5) Remove overrunning clutch from hub. (6) Mark position of annulus gear and direct clutch drum for assembly alignment reference (Fig. 160). Use small center punch or scriber to make alignment marks.
Fig.160MarkingDirectClutchDrumAndAnnulus
GearForAssemblyAlignment
1 - DIRECT CLUTCH DRUM 2 - HAMMER 3 - PUNCH
(7) Remove direct clutch drum rear retaining ring
(8) Remove direct clutch drum outer retaining ring
(Fig. 161).
(Fig. 162).
(9) Mark annulus gear and output shaft for assem- bly alignment reference (Fig. 163). Use punch or scriber to mark gear and shaft.
Fig.162ClutchDrumOuterRetainingRingRemoval 1 - OUTER RETAINING RING
Fig.163MarkingAnnulusGearAndOutputShaft
ForAssemblyAlignment
1 - OUTPUT SHAFT 2 - HAMMER 3 - PUNCH
Fig.161ClutchDrumInnerRetainingRingRemoval 1 - INNER RETAINING RING 2 - DIRECT CLUTCH DRUM 3 - ANNULUS GEAR
DR OVERDRIVE UNIT (Continued)
(10) Remove snap-ring that secures annulus gear on output shaft (Fig. 164). Use two screwdrivers to unseat and work snap-ring out of groove as shown.
(11) Remove annulus gear from output shaft (Fig. 165). Use rawhide or plastic mallet to tap gear off shaft.
Fig.164AnnulusGearSnap-RingRemoval
1 - OUTPUT SHAFT 2 - ANNULUS GEAR 3 - SNAP-RING
Fig.165AnnulusGearRemoval
1 - OUTPUT SHAFT 2 - ANNULUS GEAR
GEAR CASE AND PARK LOCK
(1) Remove locating ring from gear case. (2) Remove park pawl shaft retaining bolt and
remove shaft, pawl and spring.
(3) Remove reaction plug snap-ring and remove
reaction plug.
(4) Remove output shaft seal.
AUTOMATIC TRANSMISSION - 46RE
21 - 227
CLEANING
Clean the geartrain and case components with sol- vent. Dry all parts except the bearings with com- pressed air. Allow bearings to air dry.
Do not use shop towels for wiping parts dry unless the towels are made from a lint-free material. A suf- ficient quantity of lint (from shop towels, cloths, rags, etc.) could plug the transmission filter and fluid pas- sages.
Discard the old case gasket and seals. Do not attempt to salvage these parts. They are not reus- able. Replace any of the overdrive unit snap-rings if distorted or damaged.
Minor nicks or scratches on components can be smoothed with crocus cloth. However, do not attempt to reduce severe scoring on any components with abrasive materials. Replace severely scored compo- nents; do not try to salvage them.
INSPECTION
Check condition of the park lock components and
the overdrive case.
Check the bushings in the overdrive case. Replace the bushings if severely scored or worn. Also replace the case seal if loose, distorted, or damaged.
Examine the overdrive and direct clutch discs and plates. Replace the discs if the facing is worn, severely scored, or burned and flaking off. Replace the clutch plates if worn, heavily scored, or cracked. Check the lugs on the clutch plates for wear. The plates should slide freely in the drum. Replace the plates or drum if binding occurs.
Check condition of the annulus gear, direct clutch hub, clutch drum and clutch spring. Replace the gear, hub and drum if worn or damaged. Replace the spring if collapsed, distorted, or cracked.
Be sure the splines and lugs on the gear, drum and hub are in good condition. The clutch plates and discs should slide freely in these components.
Inspect
the thrust bearings and spring plate. Replace the plate if worn or scored. Replace the bear- ings if rough, noisy, brinnelled, or worn.
Inspect the planetary gear assembly and the sun gear and bushings. If either the sun gear or the bushings are damaged, replace the gear and bush- ings as an assembly. The gear and bushings are not serviced separately.
The planetary carrier and pinions must be in good condition. Also be sure the pinion pins are secure and in good condition. Replace the carrier if worn or dam- aged.
Inspect the overrunning clutch and race. The race surface should be smooth and free of scores. Replace the overrunning clutch assembly or the race if either assembly is worn or damaged in any way.
21 - 228
OVERDRIVE UNIT (Continued)AUTOMATIC TRANSMISSION - 46RE
DR
Replace the shaft pilot bushing and inner bushing if damaged. Replace either shaft bearing if rough or noisy. Replace the bearing snap-rings if distorted or cracked.
Check the machined surfaces on the output shaft. These surfaces should clean and smooth. Very minor nicks or scratches can be smoothed with crocus cloth. Replace the shaft if worn, scored or damaged in any way.
Inspect the output shaft bushings. The small bush- ing is the intermediate shaft pilot bushing. The large bushing is the overrunning clutch hub bushing. Replace either bushing if scored, pitted, cracked, or worn.
(3) Install annulus gear
if removed. Then install annulus gear retaining snap- ring (Fig. 167).
on output
shaft,
(4) Align and install clutch drum on annulus gear (Fig. 168). Be sure drum is engaged in annulus gear lugs.
(5) Install clutch drum outer retaining ring (Fig.
168).
ASSEMBLY
GEARTRAIN AND DIRECT CLUTCH
(1) Soak direct clutch and overdrive clutch discs in Mopart ATF +4, Automatic Transmission fluid. Allow discs to soak for 10-20 minutes.
(2) Install new pilot bushing and clutch hub bush- ing in output shaft if necessary (Fig. 166). Lubricate bushings with petroleum jelly, or transmission fluid.
Fig.167AnnulusGearInstallation
1 - SNAP-RING 2 - OUTPUT SHAFT FRONT BEARING 3 - ANNULUS GEAR
Fig.166OutputShaftPilotBushing
1 - OUTPUT SHAFT HUB 2 - OVERRUNNING CLUTCH HUB BUSHING 3 - INTERMEDIATE SHAFT PILOT BUSHING
Fig.168ClutchDrumAndOuterRetainingRing
Installation
1 - ANNULUS GEAR 2 - OUTER SNAP-RING 3 - CLUTCH DRUM
DR OVERDRIVE UNIT (Continued)
AUTOMATIC TRANSMISSION - 46RE
21 - 229
(6) Slide clutch drum forward and install
inner
retaining ring (Fig. 169).
(7) Install rear bearing and snap ring on output shaft (Fig. 170). Be sure locating ring groove in bear- ing is toward rear.
Fig.169ClutchDrumInnerRetainingRing
Installation
1 - ANNULUS GEAR 2 - INNER SNAP-RING 3 - CLUTCH DRUM
Fig.170RearBearingAndSnap-RingInstallation 1 - REAR BEARING 2 - SNAP-RING
(8) Install overrunning clutch on hub (Fig. 171). Note that clutch only fits one way. Shoulder on clutch should seat in small recess at edge of hub.
(9) Install thrust bearing on overrunning clutch hub. Use generous amount of petroleum jelly to hold bearing in place for installation. Bearing fits one way only. Be sure bearing is seated squarely against hub. Reinstall bearing if it does not seat squarely.
(10) Install overrunning clutch in output shaft (Fig. 172). Insert snap ring pliers in hub splines. Expand pliers to grip hub. Then install assembly with counterclockwise, twisting motion.
Fig.171AssemblingOverrunningClutchAndHub 1 - CLUTCH HUB 2 - OVERRUNNING CLUTCH
Fig.172OverrunningClutchInstallation
1 - CLUTCH DRUM 2 - OVERRUNNING CLUTCH ASSEMBLY 3 - EXPANDING-TYPE SNAP-RING PLIERS 4 - CLUTCH DRUM 5 - ANNULUS GEAR 6 - OVERRUNNING CLUTCH ASSEMBLY SEATED IN OUTPUT SHAFT
21 - 230
OVERDRIVE UNIT (Continued)AUTOMATIC TRANSMISSION - 46RE
(11) Install planetary gear in annulus gear (Fig. 173). Be sure planetary pinions are fully seated in annulus gear before proceeding.
DR
Fig.175SunGearInstallation
1 - SUN GEAR AND SPRING PLATE ASSEMBLY
(15) Mount assembled output shaft, annulus gear, and clutch drum in shop press. Direct clutch spring, hub and clutch pack are easier to install with assem- bly mounted in press.
(16) Align splines in hubs of planetary gear and overrunning clutch with Alignment tool 6227-2 (Fig. 176). Insert tool through sun gear and into splines of both hubs. Be sure alignment tool is fully seated before proceeding.
Fig.173PlanetaryGearInstallation
1 - PLANETARY GEAR 2 - ANNULUS GEAR
(12) Coat planetary thrust bearing and bearing contact surface of spring plate with generous amount of petroleum jelly. This will help hold bearing in place during installation.
(13) Install planetary thrust bearing on sun gear (Fig. 174). Slide bearing onto gear and seat it against spring plate as shown. Bearing fits one way only. If it does not seat squarely against spring plate, remove and reposition bearing.
(14) Install assembled sun gear, spring plate and thrust bearing (Fig. 175). Be sure sun gear and thrust bearing are fully seated before proceeding.
Fig.174PlanetaryThrustBearingInstallation
Fig.176AlignmentToolInstallation
1 - SPRING PLATE 2 - PLANETARY THRUST BEARING 3 - SUN GEAR
1 - SPECIAL TOOL 6227-2
2 - PRESS PLATES 3 - ASSEMBLED DRUM AND ANNULUS GEAR 4 - SUN GEARDR OVERDRIVE UNIT (Continued)
AUTOMATIC TRANSMISSION - 46RE
21 - 231
(17) Install direct clutch spring (Fig. 177). Be sure
spring is properly seated on spring plate.
Splines at rear of hub are raised slightly. Counter- bore in plate fits over raised splines. Plate should be flush with this end of hub (Fig. 179).
Fig.177DirectClutchSpringInstallation
1 - SPECIAL TOOL 6227-2
2 - DIRECT CLUTCH SPRING 3 - CLUTCH HUB 4 - PRESS PLATESNOTE: The direct clutch in a 46RE transmission uses 8 clutch discs.
(18) Assemble and install direct clutch pack on
hub as follows:
(a) Assemble clutch pack components (Fig. 178). (b) Install direct clutch reaction plate on clutch hub first. Note that one side of reaction plate is counterbored. Be sure this side faces rearward.
Fig.179CorrectPositionOfDirectClutchReaction
Plate
1 - REACTION PLATE COUNTERBORE 2 - DIRECT CLUTCH REACTION PLATE (FLUSH WITH END OF HUB) 3 - CLUTCH HUB
1 - CLUTCH DISCS (8) 2 - PRESSURE PLATE
3 - CLUTCH PLATES (7) 4 - REACTION PLATE
Fig.17846REDirectClutchPackComponents
21 - 232
OVERDRIVE UNIT (Continued)AUTOMATIC TRANSMISSION - 46RE
(c) Install first clutch disc followed by a steel plate until all discs and plates have been installed. (d) Install pressure plate. This is last clutch pack item to be installed. Be sure plate is installed with shoulder side facing upward (Fig. 180). (19) Install clutch hub and clutch pack on direct clutch spring (Fig. 181). Be sure hub is started on sun gear splines before proceeding.
DR
WARNING: THE NEXT STEP IN GEARTRAIN ASSEM- BLY INVOLVES COMPRESSING THE DIRECT CLUTCH HUB AND SPRING. IT IS EXTREMELY IMPORTANT THAT PROPER EQUIPMENT BE USED TO COMPRESS THE SPRING AS SPRING FORCE IS APPROXIMATELY 830 POUNDS. USE COMPRESSOR TOOL C-6227-1
AND A HYDRAULIC-TYPE SHOP PRESS WITH A MINI- MUM RAM TRAVEL OF 6 INCHES. THE PRESS MUST ALSO HAVE A BED THAT CAN BE ADJUSTED UP OR DOWN AS REQUIRED. RELEASE CLUTCH SPRING TENSION SLOWLY AND COMPLETELY TO AVOID PER- SONAL INJURY.(20) Position Compressor Tool 6227-1 on clutch
hub.
(21) Compress clutch hub and spring just enough
to place tension on hub and hold it in place.
(22) Slowly compress clutch hub and spring. Com- press spring and hub only enough to expose ring grooves for clutch pack snap ring and clutch hub retaining ring.
(23) Realign clutch pack on hub and seat clutch
discs and plates in clutch drum.
(24) Install direct clutch pack snap ring (Fig. 182). Be very sure snap ring is fully seated in clutch drum ring groove.
(25) Install clutch hub retaining ring (Fig. 183). Be very sure retaining ring is fully seated in sun gear ring groove.
(26) Slowly release press ram, remove compressor
tools and remove geartrain assembly.
Fig.180CorrectPositionOfDirectClutch
1 - DIRECT CLUTCH PRESSURE PLATE 2 - CLUTCH PACK 3 - BE SURE SHOULDER SIDE OF PLATE FACES UPWARD
Fig.181DirectClutchPackAndClutchHub
Installation
1 - CLUTCH HUB 2 - DIRECT CLUTCH PACK 3 - CLUTCH DRUM
Fig.182DirectClutchPackSnap-RingInstallation 1 - SPECIAL TOOL 6227-1
2 - DIRECT CLUTCH PACK SNAP-RINGGEAR CASE
(1) Position park pawl and spring in case and install park pawl shaft. Verify that end of spring with 90° bend is hooked to pawl and straight end of spring is seated against case.
DR OVERDRIVE UNIT (Continued)
AUTOMATIC TRANSMISSION - 46RE
21 - 233
Fig.183ClutchHubRetainingRingInstallation
1 - SPECIAL TOOL 6227-1
2 - CLUTCH HUB RETAINING RINGFig.185ReactionPlugAndSnap-RingInstallation 1 - REACTION PLUG SNAP-RING 2 - SNAP-RING PLIERS
(2) Install pawl shaft retaining bolt. Tighten bolt
to 27 N·m (20 ft. lbs.) torque.
(3) Install park lock reaction plug. Note that plug has locating pin at rear (Fig. 184). Be sure pin is seated in hole in case before installing snap ring.
(4) Install reaction plug snap-ring (Fig. 185). Com- press snap ring only enough for installation; do not distort it.
(5) Install new seal
in gear case. Use Handle
C-4171 and Installer C-3995-A to seat seal in case.
(6) Verify that tab ends of rear bearing locating ring extend into access hole in gear case (Fig. 186).
Fig.184ReactionPlugLocatingPinAndSnap-Ring 1 - REACTION PLUG SNAP-RING (DO NOT OVERCOMPRESS TO INSTALL) 2 - LOCATING PIN 3 - PARK LOCK REACTION PLUG
Fig.186CorrectRearBearingLocatingRing
Position
1 - CASE ACCESS HOLE 2 - TAB ENDS OF LOCATING RING
21 - 234
OVERDRIVE UNIT (Continued)AUTOMATIC TRANSMISSION - 46RE
DR
(7) Support geartrain on Tool 6227-1 (Fig. 187). Be
sure tool is securely seated in clutch hub.
(8) Install overdrive gear case on geartrain (Fig.
187).
Fig.189LocatingRingAccessCoverAndGasket
Installation
1 - TORX SCREWDRIVER (T25) 2 - ACCESS COVER SCREWS
(1) Install overdrive clutch reaction ring first.
Reaction ring is flat with notched ends (Fig. 190).
(2) Install wave spring on top of reaction ring (Fig. 191). Reaction ring and wave ring both fit in same ring groove. Use screwdriver to seat each ring securely in groove. Also ensure that the ends of the two rings are offset from each other.
Fig.187OverdriveGearCaseInstallation
1 - GEARTRAIN ASSEMBLY 2 - GEAR CASE
(9) Expand front bearing locating ring with snap ring pliers (Fig. 188). Then slide case downward until locating ring locks in bearing groove and release snap ring.
(10) Install locating ring access cover and gasket
in overdrive unit case (Fig. 189).
Fig.190OverdriveClutchReactionRingInstallation 1 - REACTION RING 2 - CLUTCH HUB
Fig.188SeatingLocatingRingInRearBearing
1 - EXPAND BEARING LOCATING RING WITH SNAP-RING PLIERS 2 - ACCESS HOLE
OVERDRIVE CLUTCH
NOTE: The overdrive clutch in a 46RE transmission uses 4 clutch discs.
Fig.191OverdriveClutchWaveSpringInstallation 1 - WAVE SPRING
AUTOMATIC TRANSMISSION - 46RE
21 - 235
output shaft is not loaded and internal components are moved rearward for accurate measurement.
(2) Determine correct thickness intermediate shaft
spacer as follows:
(a) Insert Special Tool 6312 through sun gear, planetary gear and into pilot bushing in output shaft. Be sure tool bottoms against planetary shoulder.
(b) Position Gauge Tool 6311 across face of over- drive case (Fig. 194). Then position Dial Caliper C-4962 over gauge tool.
(c) Extend sliding scale of dial caliper downward through gauge tool slot until scale contacts end of Gauge Alignment Tool 6312. Lock scale in place. Remove dial caliper tool and note distance mea- sured (Fig. 194).
(d) Select proper thickness end play spacer from spacer chart based on distance measured (Fig. 195).
(e) Remove Gauge Alignment Tool 6312.
DR OVERDRIVE UNIT (Continued)
(3) Assemble overdrive clutch pack (Fig. 192).
Fig.19246REOverdriveClutchComponents
1 - REACTION PLATE 2 - CLUTCH PLATES (3)
3 - PRESSURE PLATE 4 - CLUTCH DISCS (4)
(4) Install overdrive clutch reaction plate first.
NOTE: The reaction plate is the same thickness as the pressure plate in a 46RE transmission.
(5) Install first clutch disc followed by first clutch plate. Then install remaining clutch discs and plates in same order.
(6) Install clutch pack pressure plate. (7) Install clutch pack wire-type retaining ring
(Fig. 193).
Fig.194ShaftEndPlayMeasurement
1 - SPECIAL TOOL 6312
2 - SPECIAL TOOL 6311
3 - SPECIAL TOOL C-4962Fig.193OverdriveClutchPackRetainingRing
Installation
1 - OVERDRIVE CLUTCH PACK RETAINING RING
INTERMEDIATE SHAFT SPACER SELECTION
(1) Place overdrive unit in vertical position. Mount it on blocks, or in workbench with appropriate size mounting hole cut into it. Be sure unit is facing upward for access to direct clutch hub. Also be sure
Fig.195IntermediateShaftEndPlaySpacer
Selection
AUTOMATIC TRANSMISSION - 46RE
21 - 236
OVERDRIVE UNIT (Continued) OD THRUST PLATE SELECTIONDR
(1) Place overdrive unit in vertical position. Mount it on blocks, or in workbench with appropriate size mounting hole cut into it. Be sure unit is facing upward for access to direct clutch hub. Also be sure output shaft is not loaded and internal components are moved rearward for accurate measurement.
(2) Determine correct thickness overdrive piston
thrust plate as follows:
(a) Position Gauge Tool 6311 across face of over- drive case. Then position Dial Caliper C-4962 over gauge tool (Fig. 196).
(b) Measure distance to clutch hub thrust bear- ing seat at four points 90° apart. Then average measurements by adding them and dividing by 4. (c) Select and install required thrust plate from
information in thrust plate chart (Fig. 197). (3) Leave Alignment Tool 6227-2 in place. Tool will keep planetary and clutch hub splines in alignment until overdrive unit is ready for installation on trans- mission.
(4) Transmission speed sensor can be installed at this time if desired. However, it is recommended that sensor not be installed until after overdrive unit is secured to transmission.
Fig.197OverdrivePistonThrustPlateSelection
(a) Aligning locating lugs on overdrive piston to
the two mating holes in retainer.
(b) Lubricate overdrive piston seals with Mopart
Door Ease, or equivalent.
(c) Install piston over Seal Guide 8114–3 and
inside Guide Ring 8114–1.
(d) Push overdrive piston into position in
(e) Verify that the locating lugs entered the lug
bores in the retainer. (6) Install intermediate shaft spacer on intermedi-
(7) Install overdrive piston thrust plate on over-
(8) Install overdrive piston thrust bearing on over-
(9) Install transmission speed sensor and O-ring
retainer.
ate shaft.
drive piston.
drive piston.
seal in overdrive case.
INSTALLATION
Fig.196OverdrivePistonThrustPlateMeasurement 1 - SPECIAL TOOL 6311
2 - DIRECT CLUTCH HUB THRUST BEARING SEAT 3 - SPECIAL TOOL C-4962OVERDRIVE PISTON
(1) Install new seals on overdrive piston. (2) Stand transmission case upright on bellhous-
ing.
(3) Position Guide Ring 8114-1 on outer edge of
overdrive piston retainer.
overdrive piston retainer.
(4) Position Seal Guide 8114-3 on inner edge of
(5) Install overdrive piston in overdrive piston
retainer by:
(1) Be sure overdrive unit Alignment Tool 6227-2
is fully seated before moving unit. If tool is not seated and gear splines rotate out of alignment, over- drive unit will have to be disassembled in order to realign splines.(2) If overdrive piston retainer was not removed during service and original case gasket is no longer reusable, prepare new gasket by trimming it.
(3) Cut out old case gasket around piston retainer
with razor knife (Fig. 198).
(4) Use old gasket as template and trim new gas-
ket to fit.
(5) Position new gasket over piston retainer and on transmission case. Use petroleum jelly to hold gasket in place if necessary. Do not use any type of sealer to secure gasket. Use petroleum jelly only.
(6) Install selective spacer on intermediate shaft, if removed. Spacer goes in groove just rearward of shaft rear splines (Fig. 199).
DR OVERDRIVE UNIT (Continued)
AUTOMATIC TRANSMISSION - 46RE
21 - 237
rotate out of alignment. If this occurs, it will be nec- essary to remove and disassemble overdrive unit to realign splines.
(11) Work overdrive unit forward on intermediate
shaft until seated against transmission case.
(12) Install bolts attaching overdrive unit to trans- mission unit. Tighten bolts in diagonal pattern to 34
N·m (25 ft-lbs).(13) Connect the transmission speed sensor and
overdrive wiring connectors.
(14) Install the transfer case, if equipped. (15) Align and install rear propeller shaft, if nec- essary. (Refer to 3 - DIFFERENTIAL & DRIVELINE/ PROPELLER INSTALLATION)
SHAFT/PROPELLER
SHAFT
Fig.198TrimmingOverdriveCaseGasket
1 - GASKET 2 - SHARP KNIFE
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER DESCRIPTION
The overrunning clutch (Fig. 200) consists of an inner race, an outer race (or cam), rollers and springs, and the spring retainer. The number of roll- ers and springs depends on what transmission and which overrunning clutch is being dealt with.
Fig.199IntermediateShaftSelectiveSpacer
Location
1 - SELECTIVE SPACER 2 - SPACER GROOVE 3 - INTERMEDIATE SHAFT
(7) Install thrust bearing in overdrive unit sliding hub. Use petroleum jelly to hold bearing in position.
CAUTION: Be sure the shoulder on the inside diam- eter of the bearing is facing forward.
(8) Verify that splines in overdrive planetary gear and overrunning clutch hub are aligned with Align- ment Tool 6227-2. Overdrive unit cannot be installed if splines are not aligned. If splines have rotated out of alignment, unit will have to be disassembled to realign splines.
(9) Carefully slide Alignment Tool 6227-2 out of overdrive planetary gear and overrunning clutch splines.
(10) Raise overdrive unit and carefully slide it straight onto intermediate shaft. Insert park rod into park lock reaction plug at same time. Avoid tilting overdrive during installation as this could cause planetary gear and overrunning clutch splines to
Fig.200OverrunningClutch
1 - OUTER RACE (CAM) 2 - ROLLER 3 - SPRING 4 - SPRING RETAINER 5 - INNER RACE (HUB)
OPERATION
As the inner race is rotated in a clockwise direction (as viewed from the front of the transmission), the race causes the rollers to roll toward the springs, causing them to compress against their retainer. The compression of the springs increases the clearance
21 - 238
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued)AUTOMATIC TRANSMISSION - 46RE
DR
between the rollers and cam. This increased clear- ance between the rollers and cam results in a free- wheeling condition. When the inner race attempts to rotate counterclockwise, the action causes the rollers to roll in the same direction as the race, aided by the pushing of the springs. As the rollers try to move in the same direction as the inner race, they are wedged between the inner and outer races due to the design of the cam. In this condition, the clutch is locked and acts as one unit.
DISASSEMBLY
(1) Remove the overdrive piston (Fig. 201). (2) Remove the overdrive piston retainer bolts. (3) Remove overdrive piston retainer. (4) Remove case gasket. (5) Tap old cam out of case with pin punch. Insert punch through bolt holes at rear of case (Fig. 202). Alternate position of punch to avoid cocking cam dur- ing removal.
(6) Clean clutch cam bore and case. Be sure to remove all chips/shavings generated during cam removal.
Fig.201OverdrivePistonRemoval
1 - OVERDRIVE CLUTCH PISTON 2 - INTERMEDIATE SHAFT 3 - SELECTIVE SPACER 4 - PISTON RETAINER
Fig.202OverrunningClutchCam
1 - PIN PUNCH 2 - REAR SUPPORT BOLT HOLES
CLEANING
Clean the overrunning clutch assembly, clutch cam, low-reverse drum, and overdrive piston retainer in solvent. Dry them with compressed air after clean- ing.
INSPECTION
Inspect condition of each clutch part after cleaning. Replace the overrunning clutch roller and spring assembly if any rollers or springs are worn or dam- aged, or if the roller cage is distorted, or damaged. Replace the cam if worn, cracked or damaged.
Replace the low-reverse drum if the clutch race, roller surface or inside diameter is scored, worn or damaged. Do not remove the clutch race from the low-reverse drum under any circumstances. Replace the drum and race as an assembly if either component is damaged.
Examine the overdrive piston retainer carefully for wear, cracks, scoring or other damage. Be sure the retainer hub is a snug fit in the case and drum. Replace the retainer if worn or damaged.
DR OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued) ASSEMBLY
AUTOMATIC TRANSMISSION - 46RE
21 - 239
(1) Temporarily install overdrive piston retainer in
case. Use 3-4 bolts to secure retainer.
(2) Align and start new clutch cam in the trans- mission case. Be sure serrations on cam and in case are aligned (Fig. 203). Then tap cam into case just enough to hold it in place.
(3) Verify that cam is correctly positioned before proceeding any further. Narrow ends of cam ramps should be to left when cam is viewed from front end of case (Fig. 203).
(4) Insert Adapter Tool SP-5124 into piston
retainer (Fig. 204).
SP-3583-A (Fig. 205).
(5) Assemble Puller Bolt SP-3701 and Press Plate
Fig.205AssemblingClutchCamPullerBoltAnd
PressPlate
1 - PULLER BOLT SP-3701
2 - PRESS PLATE SP-3583-A(6) Install assembled puller plate and bolt (Fig. 206). Insert bolt through cam, case and adapter tool. Be sure plate is seated squarely on cam.
Fig.203PositioningReplacementClutchCamIn
Case
1 - ALIGN SERRATIONS ON CAM AND IN CASE 2 - CLUTCH CAM
Fig.206PositioningPullerPlateOnClutchCam
1 - SPECIAL TOOL SP-3701
2 - BE SURE PLATE SP-3583-A IS SEATED SQUARELY ON CAMFig.204PositioningAdapterToolInOverdrive
PistonRetainer
1 - PISTON RETAINER 2 - SPECIAL TOOL SP-5124
21 - 240
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued)AUTOMATIC TRANSMISSION - 46RE
DR
(7) Hold puller plate and bolt in place and install
puller nut SP-3701 on puller bolt (Fig. 207).
(8) Tighten puller nut to press clutch cam into case (Fig. 207). Be sure cam is pressed into case evenly and does not become cocked.
(9) Remove clutch cam installer tools. (10) Stake case in 14 places around clutch cam to help secure cam in case. Use blunt punch or chisel to stake case.
(11) Remove piston retainer
from case. Cover retainer with plastic sheeting, or paper to keep it dust free.
(12) Clean case and cam thoroughly. Be sure any chips/shavings generated during cam installation are removed from case.
Fig.208Installing/AligningCaseGasket
1 - CASE GASKET 2 - BE SURE GOVERNOR TUBE FEED HOLES IN CASE AND GASKET ARE ALIGNED
Fig.209AligningOverdrivePistonRetainer
1 - PISTON RETAINER 2 - GASKET 3 - RETAINER BOLTS
(17) Position Guide Ring 8114-1 on outer edge of
overdrive piston retainer.
overdrive piston retainer.
(18) Position Seal Guide 8114-3 on inner edge of
Fig.207PressingOverrunningClutchCamInto
Case
1 - SPECIAL TOOL SP-3583-A 2 - TIGHTEN NUT TO DRAW CAM INTO CASE (NUT IS PART OF BOLT SP-3701) 3 - SPECIAL TOOL SP-5124
4 - SPECIAL TOOL SP-3701(13) Install new gasket at rear of transmission case. Use petroleum jelly to hold gasket in place. Be sure to align governor feed holes in gasket with feed passages in case (Fig. 208). Also install gasket before overdrive piston retainer. Center hole in gasket is smaller than retainer and cannot be installed over retainer.
(14) Position overdrive piston retainer on trans- mission case and align bolt holes in retainer, gasket and case (Fig. 209). Then install and tighten retainer bolts to 17 N·m (13 ft. lbs.) torque.
(15) Install new seals on overdrive piston. (16) Stand transmission case upright on bellhous-
ing.
DR OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued)
AUTOMATIC TRANSMISSION - 46RE
21 - 241
(19) Install overdrive piston in overdrive piston retainer by: aligning locating lugs on overdrive piston to the two mating holes in retainer.
(a) Aligning locating lugs on overdrive piston to
the two mating holes in retainer.
(b) Lubricate overdrive piston seals with Mopart
Door Ease, or equivalent.
inside Guide Ring 8114-1.
(c) Install piston over Seal Guide 8114-3 and
(d) Push overdrive piston into position in
retainer.
(e) Verify that the locating lugs entered the lug
bores in the retainer.
PISTONS DESCRIPTION
There are several sizes and types of pistons used in an automatic transmission. Some pistons are used to apply clutches, while others are used to apply bands. They all have in common the fact that they are round or circular in shape, located within a smooth walled cylinder, which is closed at one end and con- verts fluid pressure into mechanical movement. The fluid pressure exerted on the piston is contained within the system through the use of piston rings or seals.
OPERATION
The principal which makes this operation possible is known as Pascal’s Law. Pascal’s Law can be stated as: “Pressure on a confined fluid is transmitted equally in all directions and acts with equal force on equal areas.”
PRESSURE
Pressure (Fig. 210)
is nothing more than force (lbs.) divided by area (in or ft.), or force per unit area. Given a 100 lb. block and an area of 100 sq. in. on the floor, the pressure exerted by the block is: 100
lbs. 100 in or 1 pound per square inch, or PSI as it is commonly referred to.PRESSURE ON A CONFINED FLUID
Pressure is exerted on a confined fluid (Fig. 211) by applying a force to some given area in contact with the fluid. A good example of this is a cylinder filled with fluid and equipped with a piston that is closely fitted to the cylinder wall. If a force is applied to the piston, pressure will be developed in the fluid. Of course, no pressure will be created if the fluid is not confined. It will simply “leak” past the piston. There must be a resistance to flow in order to create pres- sure. Piston sealing is extremely important in hydraulic operation. Several kinds of seals are used
Fig.210ForceandPressureRelationship
to accomplish this within a transmission. These include but are not limited to O-rings, D-rings, lip seals, sealing rings, or extremely close tolerances between the piston and the cylinder wall. The force exerted is downward (gravity), however, the principle remains the same no matter which direction is taken. The pressure created in the fluid is equal to the force applied, divided by the piston area. If the force is 100
lbs., and the piston area is 10 sq. in., then the pres- sure created equals 10 PSI. Another interpretation of Pascal’s Law is that regardless of container shape or size, the pressure will be maintained throughout, as long as the fluid is confined. In other words, the pressure in the fluid is the same everywhere within the container.Fig.211PressureonaConfinedFluid
DR
AUTOMATIC TRANSMISSION - 46RE
21 - 242
PISTONS (Continued) FORCE MULTIPLICATIONUsing the 10 PSI example used in the illustration (Fig. 212), a force of 1000 lbs. can be moved with a force of only 100 lbs. The secret of force multiplica- tion in hydraulic systems is the total fluid contact area employed. The illustration, (Fig. 212), shows an area that is ten times larger than the original area. The pressure created with the smaller 100 lb. input is 10 PSI. The concept “pressure is the same every- where” means that the pressure underneath the larger piston is also 10 PSI. Pressure is equal to the force applied divided by the contact area. Therefore, by means of simple algebra, the output force may be found. This concept is extremely important, as it is also used in the design and operation of all shift valves and limiting valves in the valve body, as well as the pistons, of the transmission, which activate the clutches and bands. It is nothing more than using a difference of area to create a difference in pressure to move an object.
Fig.213PistonTravel
PLANETARY GEARTRAIN/ OUTPUT SHAFT DESCRIPTION
The planetary gearsets (Fig. 214) are designated as the front, rear, and overdrive planetary gear assem- blies and located in such order. A simple planetary gearset consists of three main members:
Fig.212ForceMultiplication
PISTON TRAVEL
The relationship between hydraulic lever and a mechanical lever is the same. With a mechanical lever it’s a weight-to-distance output rather than a pressure-to-area output. Using the same forces and areas as in the previous example, the smaller piston (Fig. 213) has to move ten times the distance required to move the larger piston one inch. There- fore, for every inch the larger piston moves, the smaller piston moves ten inches. This principle is true in other instances also. A common garage floor jack is a good example. To raise a car weighing 2000
lbs., an effort of only 100 lbs. may be required. For every inch the car moves upward, the input piston at the jack handle must move 20 inches downward.Fig.214PlanetaryGearset
1 - ANNULUS GEAR 2 - SUN GEAR 3 - PLANET CARRIER 4 - PLANET PINIONS (4)
AUTOMATIC TRANSMISSION - 46RE
DR PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued) † The sun gear which is at the center of the sys- tem.† The planet carrier with planet pinion gears which are free to rotate on their own shafts and are in mesh with the sun gear. † The annulus gear, which rotates around and is in mesh with the planet pinion gears.
21 - 243
NOTE: The number of pinion gears does not affect the gear ratio, only the duty rating.
OPERATION
With any given planetary gearset, several condi- tions must be met for power to be able to flow: † One member must be held. † Another member must be driven or used as an input.† The third member may be used as an output for power flow. † For direct drive to occur, two gear members in
the front planetary gearset must be driven.
NOTE: Gear ratios are dependent on the number of teeth on the annulus and sun gears.
DISASSEMBLY
Fig.216RemovingFrontPlanetaryAndAnnulus
Gears
1 - DRIVING SHELL 2 - FRONT ANNULUS GEAR 3 - FRONT PLANETARY GEAR
(1) Remove planetary snap-ring from intermediate shaft (Fig. 215). Discard snap-ring as it is not reus- able.
(2) Remove front planetary gear and front annulus
gear as assembly (Fig. 216).
(3) Remove
front planetary gear and thrust washer from front annulus gear (Fig. 217). Note thrust washer position for assembly reference.
Fig.217DisassemblingFrontPlanetaryAnd
AnnulusGears
1 - FRONT PLANETARY GEAR 2 - TABBED THRUST WASHER 3 - FRONT ANNULUS GEAR
Fig.215RemovingPlanetarySnap-Ring
1 - PLANETARY SNAP-RING
21 - 244
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)AUTOMATIC TRANSMISSION - 46RE
DR
(4) Remove tabbed thrust washer from driving shell (Fig. 218). Note washer position for assembly reference.
(5) Remove sun gear and driving shell as assembly
(Fig. 219).
Fig.220RearPlanetaryThrustWasherRemoval
1 - SUN GEAR 2 - REAR PLANETARY THRUST WASHER 3 - DRIVING SHELL
Fig.218DrivingShellThrustWasherRemoval
1 - DRIVING SHELL 2 - TABBED THRUST WASHER 3 - SUN GEAR
Fig.221RearPlanetaryAndAnnulusGearRemoval 1 - INTERMEDIATE SHAFT 2 - REAR ANNULUS GEAR 3 - REAR PLANETARY GEAR
Fig.219SunGearAndDrivingShellRemoval
1 - INTERMEDIATE SHAFT 2 - DRIVING SHELL 3 - SUN GEAR
(6) Remove tabbed thrust washer from rear plane- tary gear (Fig. 220). Note washer position on gear for assembly reference.
(7) Remove rear planetary gear and rear annulus
gear from intermediate shaft (Fig. 221).
(8) Remove thrust plate from rear annulus gear
(Fig. 222).
Fig.222RearAnnulusThrustPlateRemoval
1 - REAR ANNULUS GEAR 2 - THRUST PLATE
DR PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued) INSPECTION
AUTOMATIC TRANSMISSION - 46RE
21 - 245
sun gear and against rear side of driving shell (Fig. 223). Install rear snap-ring to secure sun gear and thrust plate in driving shell.
(3) Install rear annulus gear on intermediate shaft
(Fig. 224).
(4) Install thrust plate in annulus gear (Fig. 225). Be sure plate is seated on shaft splines and against gear.
Inspect the planetary gear sets and annulus gears. The planetary pinions, shafts, washers, and retaining pins are serviceable. However, if a pinion carrier is damaged, the entire planetary gear set must be replaced as an assembly.
Replace the annulus gears if the teeth are chipped, broken, or worn, or the gear is cracked. Replace the planetary thrust plates and the tabbed thrust wash- ers if cracked, scored or worn.
Inspect the machined surfaces of the intermediate shaft. Be sure the oil passages are open and clear. Replace the shaft if scored, pitted, or damaged.
Inspect the sun gear and driving shell. If either component is worn or damaged, remove the sun gear rear retaining ring and separate the sun gear and thrust plate from the driving shell. Then replace the necessary component.
Replace the sun gear as an assembly if the gear teeth are chipped or worn. Also replace the gear as an assembly if the bushings are scored or worn. The sun gear bushings are not serviceable. Replace the thrust plate if worn, or severely scored. Replace the driving shell if distorted, cracked, or damaged in any way.
Replace all snap-rings during geartrain assembly.
Reusing snap-rings is not recommended.
ASSEMBLY
(1) Lubricate sun gear and planetary gears with transmission fluid during assembly. Use petroleum jelly to lubricate intermediate shaft bushing surfaces, thrust washers and thrust plates and to hold these parts in place during assembly.
(2) Install front snap-ring on sun gear and install gear in driving shell. Then install thrust plate over
Fig.223SunGearInstallation
1 - DRIVING SHELL 2 - SUN GEAR 3 - THRUST PLATE 4 - SUN GEAR REAR RETAINING RING
Fig.224InstallingRearAnnulusGearOn
IntermediateShaft
1 - REAR ANNULUS GEAR 2 - OUTPUT SHAFT
Fig.225InstallingRearAnnulusThrustPlate
1 - REAR ANNULUS GEAR 2 - THRUST PLATE
21 - 246
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)AUTOMATIC TRANSMISSION - 46RE
DR
(5) Install rear planetary gear in rear annulus gear (Fig. 226). Be sure planetary carrier is seated against annulus gear.
(6) Install tabbed thrust washer on front face of rear planetary gear (Fig. 227). Seat washer tabs in matching slots in face of gear carrier. Use extra petroleum jelly to hold washer in place if desired.
(7) Lubricate sun gear bushings with petroleum
jelly or transmission fluid.
(8) Install sun gear and driving shell on interme- diate shaft (Fig. 228). Seat shell against rear plane- tary gear. Verify that thrust washer on planetary gear was not displaced during installation.
(9) Install tabbed thrust washer in driving shell (Fig. 229), be sure washer tabs are seated in tab slots of driving shell. Use extra petroleum jelly to hold washer in place if desired.
Fig.228InstallingSunGearAndDrivingShell
1 - OUTPUT SHAFT 2 - DRIVING SHELL 3 - REAR PLANETARY GEAR 4 - OUTPUT SHAFT 5 - SUN GEAR
Fig.226InstallingRearPlanetaryGear
1 - REAR ANNULUS GEAR 2 - REAR PLANETARY GEAR
Fig.227InstallingRearPlanetaryThrustWasher
1 - REAR PLANETARY GEAR 2 - TABBED THRUST WASHER
Fig.229InstallingDrivingShellThrustWasher
1 - TAB SLOTS (3) 2 - DRIVING SHELL 3 - TABBED THRUST WASHER
DR PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)
AUTOMATIC TRANSMISSION - 46RE
21 - 247
(10) Install tabbed thrust washer on front plane- tary gear (Fig. 230). Seat washer tabs in matching slots in face of gear carrier. Use extra petroleum jelly to hold washer in place if desired.
Fig.231AssemblingFrontPlanetaryAndAnnulus
Gears
1 - FRONT ANNULUS GEAR 2 - FRONT PLANETARY GEAR
Fig.230InstallingThrustWasherOnFront
PlanetaryGear
1 - TABBED THRUST WASHER 2 - FRONT PLANETARY GEAR
(11) Install front annulus gear over and onto front planetary gear (Fig. 231). Be sure gears are fully meshed and seated.
(12) Install
front planetary and annulus gear assembly (Fig. 232). Hold gears together and slide them onto shaft. Be sure planetary pinions are seated on sun gear and that planetary carrier is seated on intermediate shaft.
(13) Place geartrain in upright position. Rotate gears to be sure all components are seated and prop- erly assembled. Snap-ring groove at forward end of intermediate shaft will be completely exposed when components are assembled correctly.
Fig.232InstallingFrontPlanetaryAndAnnulus
GearAssembly
1 - DRIVING SHELL 2 - ASSEMBLED FRONT PLANETARY AND ANNULUS GEARS
21 - 248
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)AUTOMATIC TRANSMISSION - 46RE
DR
(14) Install new planetary snap-ring in groove at
end of intermediate shaft (Fig. 233).
(15) Turn planetary geartrain over. Position wood block under front end of intermediate shaft and sup- port geartrain on shaft. Be sure all geartrain parts have moved forward against planetary snap-ring. This is important for accurate end play check.
(16) Check planetary geartrain end play with feeler gauge (Fig. 234). Insert gauge between rear annulus gear and shoulder on intermediate shaft as shown. End play should be 0.15 to 1.22 mm (0.006 to 0.048 in.).
(17) If end play is incorrect, install thinner/thicker
planetary snap-ring as needed.
Fig.234CheckingPlanetaryGeartrainEndPlay
1 - OUTPUT SHAFT 2 - REAR ANNULUS GEAR 3 - FEELER GAUGE
REAR CLUTCH DESCRIPTION
The rear clutch assembly (Fig. 235) is composed of the rear clutch retainer, pressure plate, clutch plates, driving discs, piston, Belleville spring, and snap- rings. The Belleville spring acts as a lever to multi- ply the force applied on to it by the apply piston. The increased apply force on the rear clutch pack, in com- parison to the front clutch pack, is needed to hold against the greater torque load imposed onto the rear pack. The rear clutch is directly behind the front clutch and is considered a driving component.
NOTE: The number of discs and plates may vary with each engine and vehicle combination.
Fig.233InstallingPlanetarySnap-Ring
1 - SNAP-RING PLIERS 2 - PLANETARY SNAP-RING
DR REAR CLUTCH (Continued)
AUTOMATIC TRANSMISSION - 46RE
21 - 249
1 - REAR CLUTCH RETAINER 2 - TORLON™ SEAL RINGS 3 - INPUT SHAFT 4 - PISTON RETAINER 5 - OUTPUT SHAFT THRUST WASHER 6 - INNER PISTON SEAL 7 - PISTON SPRING 8 - PRESSURE PLATE 9 - CLUTCH DISCS 10 - SNAP-RING (SELECTIVE)
Fig.235RearClutchComponents
11 - REACTION PLATE 12 - CLUTCH PLATES 13 - WAVE SPRING 14 - SPACER RING 15 - PISTON 16 - OUTER PISTON SEAL 17 - REAR SEAL RING 18 - FIBER THRUST WASHER 19 - RETAINING RING
OPERATION
To apply the clutch, pressure is applied between the clutch retainer and piston. The fluid pressure is provided by the oil pump, transferred through the control valves and passageways, and enters the clutch through the hub of the reaction shaft support. With pressure applied between the clutch retainer and piston, the piston moves away from the clutch retainer and compresses the clutch pack. This action applies the clutch pack, allowing torque to flow through the input shaft into the driving discs, and into the clutch plates and pressure plate that are lugged to the clutch retainer. The waved spring is used to cushion the application of the clutch pack. The snap-ring is selective and used to adjust clutch pack clearance.
When pressure is released from the piston, the spring returns the piston to its fully released position and disengages the clutch. The release spring also helps to cushion the application of the clutch assem- bly. When the clutch is in the process of being released by the release spring, fluid flows through a vent and one-way ball-check-valve located in the pis-
ton. The check-valve is needed to eliminate the pos- sibility of plate drag caused by centrifugal force acting on the residual fluid trapped in the clutch pis- ton retainer.
DISASSEMBLY
(1) Remove fiber thrust washer from forward side
of clutch retainer.
(2) Remove input shaft front and rear seal rings. (3) Remove selective clutch pack snap-ring (Fig.
236).
(4) Remove the reaction plate, clutch discs, steel plates, pressure plate, wave spring, spacer ring, and piston spring (Fig. 236).
