Usage:
(1) Input shaft
(2) Use shims as necessary to get 0.05 ± 0.05 mm (.002 ± .002 in) endplay on input shaft.
See Procedure To Set Input Shaft Bearing Endplay
(3) 6Y3867 Clutch Group (Forward Low and Forward High)
(4) 6Y8156 Clutch Group (Reverse and Second)
(5) 8E5299 Clutch Group (Third and First)
(6) 9U9284 Output Gear Group
6Y3867 Clutch Group (3)
(7) Thickness of six new discs and six new plates for the Forward Low Clutch ... 48.00 ± 0.96 mm (1.890 ± .038 in)
NOTE: This dimension is only the thickness of six new discs and six new plates. It does not include the running clearance of the clutch pack. See Procedure To Measure Running Clearance.
Thickness of one new 6Y7968 Disc ... 4.00 ± 0.08 mm (.157 ± .003 in)
Minimum allowable thickness for reusability ... 3.80 mm (.149 in)
Thickness of one new 8E0682 Plate ... 4.00 ± 0.08 mm (.157 ± .003 in)
(8) 6Y7818 Spring:
Length under test force ... 34.50 mm (1.358 in)
Test force ... 1245 ± 62 N (280 ± 14 lb)
Free length after test ... 50.37 mm (1.983 in)
Outside diameter ... 78.86 mm (3.105 in)
(9) Thickness of four new discs and four new plates for the Forward High clutch ... 28.00 ± 0.64 mm (1.102 ± .025 in)
NOTE: This dimension is only the thickness of four new discs and four new plates. It does not include the running clearance of the clutch pack. See Procedure To Measure Running Clearance.
Thickness of one new 6Y7968 Disc ... 4.00 ± 0.08 mm (.157 ± .003 in)
Minimum allowable thickness for reusability ... 3.80 mm (.149 in)
Thickness of one new 6Y5631 Plate ... 3.00 ± 0.08 mm (.118 ± .003 in)
(10) Depth to install bearing ... 1.5 ± 0.3 mm (.059 ± .012 in)
(11) Diameter of bearing after assembly ... 50.075 ± 0.039 mm (1.9715 ± .0015 in)
Diameter of shaft in bearing area ... 49.992 ± 0.008 mm (1.9682 ± .0003)
(12) Running clearance (new) ... 3.5 ± 0.5 mm (.138 ± .020 in)
See Procedure To Measure Running Clearance.
(13) Running clearance (new) ... 3.5 ± 0.5 mm (.138 ± .020 in)
See Procedure To Measure Running Clearance.
6Y8156 Clutch Group (4)
(14) 6Y6934 Coned Disc Spring
Free height ... 4.25 mm (.167 in)
Load when flattened ... 3610 ± 290 N (812 ± 65 lb)
| NOTICE |
|---|
Coned disc spring must be assembled as shown or internal transmission damage will result. |
(15) Thickness of six new discs and six new plates for the Reverse Clutch ... 48.00 ± 0.96 mm (1.890 ± .038 in)
NOTE: This dimension is only the thickness of six new discs and six new plates. It does not include the running clearance of the clutch pack. See Procedure To Measure Running Clearance.
Thickness of one new 6Y7968 Disc ... 4.00 ± 0.08 mm (.157 ± .003 in)
Minimum allowable thickness for reusability ... 3.80 mm (.149 in)
Thickness of one new 8E0682 Plate ... 4.00 ± 0.08 mm (.157 ± .003 in)
(16) 6Y7818 Spring:
Length under test force ... 34.50 mm (1.358 in)
Test force ... 1245 ± 62 N (280 ± 14 lb)
Free length after test ... 50.37 mm (1.983 in)
Outside diameter ... 78.86 mm (3.105 in)
(17) Thickness of five new discs and six new plates for the Second Gear Clutch ... 38.00 ± 0.88 mm (1.496 ± .035 in)
NOTE: This dimension is only the thickness of five new discs and six new plates. It does not include the running clearance of the clutch pack. See Procedure To Measure Running Clearance.
Thickness of one new 6Y7968 Disc ... 4.00 ± 0.08 mm (.157 ± .003 in)
Minimum allowable thickness for reusability ... 3.80 mm (.149 in)
Thickness of one new 6Y5631 Plate ... 3.00 ± 0.08 mm (.118 ± .003 in)
(18) Depth to install bearing ... 1.5 ± 0.3 mm (.059 ± .012 in)
(19) Diameter of bearing after assembly ... 50.075 ± 0.039 mm (1.9715 ± .0015 in)
Diameter of shaft in bearing area ... 49.992 ± 0.008 mm (1.9682 ± .0003)
(20) Running clearance (new) ... 3.5 ± 0.5 mm (.138 ± .020 in)
See Procedure To Measure Running Clearance.
(21) Running clearance (new) ... 3.25 ± 0.5 mm (.128 ± .020 in)
See Procedure To Measure Running Clearance.
8E5299 Clutch Group (5)
(22) 6Y8560 Coned Disc Spring
Free height ... 5.0 mm (.20 in)
Load when flattened ... 3700 ± 300 N (825 ± 67 lb)
| NOTICE |
|---|
Coned disc spring must be assembled as shown or internal transmission damage will result. |
(23) Thickness of five new discs and six new plates for the Third Gear Clutch ... 38.00 ± 0.88 mm (1.496 ± .035 in)
NOTE: This dimension is only the thickness of four new discs and five new plates. It does not include the running clearance of the clutch pack. See Procedure To Measure Running Clearance.
Thickness of one new 6Y7968 Disc ... 4.00 ± 0.08 mm (.157 ± .003 in)
Minimum allowable thickness for reusability ... 3.80 mm (.149 in)
Thickness of one new 6Y5631 Plate ... 3.00 ± 0.08 mm (.118 ± .003 in)
(24) 6Y7818 Spring:
Length under test force ... 34.50 mm (1.358 in)
Test force ... 1245 ± 62 N (280 ± 14 lb)
Free length after test ... 50.37 mm (1.983 in)
Outside diameter ... 78.86 mm (3.105 in)
(25) Thickness of eight new discs and eight new plates for the First Gear Clutch ... 48.96 ± 1.28 mm (1.928 ± .050 in)
NOTE: This dimension is only the thickness of eight new discs and eight new plates. It does not include the running clearance of the clutch pack. See Procedure To Measure Running Clearance.
Thickness of one new 6Y7922 Disc ... 4.00 ± 0.08 mm (.157 ± .003 in)
Minimum allowable thickness for reusability ... 3.80 mm (.149 in)
Thickness of one new 6Y8043 Plate ... 2.12 ± 0.08 mm (.083 ± .003 in)
(26) Depth to install bearing ... 1.0 ± 0.3 mm (.039 ± .012 in)
(27) Diameter of bearing after assembly ... 50.075 ± 0.039 mm (1.9715 ± .0015 in)
Diameter of shaft in bearing area ... 49.992 ± 0.008 mm (1.9682 ± .0003)
(28) Depth to install bearing ... 1.5 ± 0.3 mm (.059 ± .012 in)
(29) Diameter of bearing after assembly ... 65.046 ± 0.039 mm (2.5609 ± .0015 in)
Diameter of shaft in bearing area ... 64.961 ± 0.010 mm (2.5575 ± .0004)
(30) Running clearance (new) ... 3.25 ± 0.5 mm (.128 ± .020 in)
See Procedure To Measure Running Clearance.
(31) Running clearance (new) ... 2.5 ± 0.5 mm (.098 ± .020 in)
See Procedure To Measure Running Clearance.
(32) 6Y6934 Coned Disc Spring
Free height ... 4.25 mm (.167 in)
Load when flattened ... 3610 ± 290 N (812 ± 65 lb)
| NOTICE |
|---|
Coned disc spring must be assembled as shown or internal transmission damage will result. |
(33) 8E1278 Wave Spring
Length under test force ... 26.70 mm (1.051 in)
Test force (approximately) ... 413 N (93 lb)
Length under test force ... 19 mm (.75 in)
Test force ... 1417 ± 212 N (318 ± 48 lb)
Free length after test ... 29.9 mm (1.18 in)
Outside diameter ... 116.46 ± 0.64 mm (4.585 ± .025 in)
Output Gear Group
(34) Thickness of new lining ... 4.50 mm (.177 in)
Minimum allowable thickness ... 2.50 mm (.098 in)
(35) Torque for four bolts ... 120 ± 20 N·m (88 ± 15 lb ft)
(36) Torque for eight bolts ... 120 ± 20 N·m (88 ± 15 lb ft)
(37) Torque for one bolt ... 120 ± 20 N·m (88 ± 15 lb ft)
(38) Coat seal bore with 7M7260 Liquid Gasket and allow to dry before installing seal.
(39) 9W7159 Shim Pack thickness ... 3.00 mm (.120 in)
Consisting of:
Four ... 0.05 mm (.002 in)
Two ... 0.80 mm (.032 in)
Six ... 0.20 mm (.008 in)
Use shims as necessary to get 0.06 to 0.13 mm (.002 to .005 in) endplay on output shaft.
Procedure To Measure Running Clearance
Use this procedure to check for proper clutch assembly.
1. Position the assembled clutch group with the shaft in the vertical position and the end plate of the clutch to be measured facing upward.
2. Make sure end plate (2) is free.
3. Position the tip of a dial indicator on end plate (2) and zero the indicator.
 |
Personal injury can result from applying air pressure without lock ring securly in place. Make sure lock ring (3) is securely in place before applying air pressure to clutch pack. |
 |
4. Apply approximately 140 kPa (20 psi) air pressure to appropriate passage (1) in the shaft for the clutch being checked.
5. End plate (2) should move and contact lock ring (3). With the end plate contacting lock ring (3), determine the distance the end plate has moved from the dial indicator. This is the clutch pack running clearance.
NOTE: Verifying that running clearances on used clutch packs are within specification does not necessarily mean that one or two discs are not badly worn. The most effective way to measure for clutch wear is to disassemble the clutch pack and individually measure each disc for wear.
NOTE: In clutch packs that contain a coned disc spring, the running clearance assumes that the coned disc spring is not flattened when the pack is compressed for measurement.
