Toyota
Dodge Durango
 Service Manual
Transmission and Transfer Case » Disassembly and assembly
Rear clutch

DISASSEMBLY

(1) Remove fiber thrust washer from forward side of clutch retainer.

(2) Remove input shaft front/rear seal rings.

(3) Remove selective clutch pack snap ring (Fig.

214).

(4) Remove top pressure plate, clutch discs, steel plates, bottom pressure plate and wave snap ring and wave spring (Fig. 214).

(5) Remove clutch piston with rotating motion.

(6) Remove and discard piston seals.

(7) Remove input shaft snap-ring (Fig. 215). It may be necessary to press the input shaft in slightly to relieve tension on the snap-ring (8) Press input shaft out of retainer with shop press and suitable size press tool. Use a suitably sized press tool to support the retainer as close to the input shaft as possible.

ASSEMBLY

(1) Soak clutch discs in transmission fluid while assembling other clutch parts.

Fig. 214 Rear Clutch Components Fig. 214 Rear Clutch Components

1 - PISTON SPRING

2 - REAR CLUTCH PISTON

3 - CLUTCH PISTON SEALS

4 - OUTPUT SHAFT THRUST WASHER (METAL)

5 - INPUT SHAFT SNAP RING

6 - REAR CLUTCH RETAINER

7 - INPUT SHAFT

8 - REAR CLUTCH THRUST WASHER (FIBER)

9 - CLUTCH PACK SNAP RING (SELECTIVE)

10 - TOP PRESSURE PLATE

11 - CLUTCH DISCS (4)

12 - BOTTOM PRESSURE PLATE

13 - WAVE SPRING

14 - CLUTCH PLATES (3)

15 - RETAINER SEAL RING

16 - SHAFT REAR SEAL RING (PLASTIC)

17 - SHAFT FRONT SEAL RING (TEFLON)

Fig. 215 Removing/Installing Input Shaft Snap-Ring Fig. 215 Removing/Installing Input Shaft Snap-Ring

1 - REAR CLUTCH RETAINER

2 - INPUT SHAFT SNAP RING

3 - SNAP RING PLIERS

(2) Install new seal rings on clutch retainer hub and input shaft if necessary (Fig. 216).

(a) Be sure clutch hub seal ring is fully seated in groove and is not twisted.

(3) Lubricate splined end of input shaft and clutch retainer with transmission fluid. Then press input shaft into retainer. Use a suitably sized press tool to support retainer as close to input shaft as possible.

(4) Install input shaft snap-ring (Fig. 215).

(5) Invert retainer and press input shaft in opposite direction until snap-ring is seated.

(6) Install new seals on clutch piston. Be sure lip of each seal faces interior of clutch retainer.

(7) Lubricate lip of piston seals with generous quantity of Mopart Door Ease. Then lubricate retainer hub and bore with light coat of transmission fluid.

(8) Install clutch piston in retainer. Use twisting motion to seat piston in bottom of retainer. A thin strip of plastic (about 0.020" thick), can be used to guide seals into place if necessary.

CAUTION: Never push the clutch piston straight in.

This will fold the seals over causing leakage and clutch slip. In addition, never use any type of metal tool to help ease the piston seals into place. Metal tools will cut, shave, or score the seals.

(9) Install piston spring in retainer and on top of piston (Fig. 219). Concave side of spring faces downward (toward piston).

(10) Install wave spring in retainer (Fig. 219). Be sure spring is completely seated in retainer groove.

Fig. 216 Rear Clutch Retainer And Input Shaft Seal Ring Installation Fig. 216 Rear Clutch Retainer And Input Shaft Seal Ring Installation

1 - REAR CLUTCH RETAINER HUB SEAL RING

2 - INPUT SHAFT SEAL RINGS

Fig. 217 Input Shaft Seal Ring Identification Fig. 217 Input Shaft Seal Ring Identification

1 - PLASTIC REAR SEAL RING

2 - TEFLON FRONT SEAL RING (SQUEEZE RING TOGETHER SLIGHTLY BEFORE INSTALLATION FOR BETTER FIT)

(11) Install bottom pressure plate (Fig. 214).

Ridged side of plate faces downward (toward piston) and flat side toward clutch pack.

Fig. 218 Pressing Input Shaft Into Rear Clutch Retainer Fig. 218 Pressing Input Shaft Into Rear Clutch Retainer

 1 - INPUT SHAFT

2 - REAR CLUTCH RETAINER

3 - PRESS RAM

Fig. 219 Piston Spring/Wave Spring Position Fig. 219 Piston Spring/Wave Spring Position

1 - REAR CLUTCH RETAINER

2 - PISTON SPRING

3 - WAVE SPRING

4 - CLUTCH PISTON

(12) Install first clutch disc in retainer on top of bottom pressure plate. Then install a clutch plate followed by a clutch disc until entire clutch pack is installed (4 discs and 3 plates are required) (Fig.

214).

(13) Install top pressure plate.

(14) Install selective snap ring. Be sure snap ring is fully seated in retainer groove.

(15) Using a suitable gauge bar and dial indicator, measure clutch pack clearance (Fig. 220).

(a) Position gauge bar across the clutch drum with the dial indicator pointer on the pressure plate (Fig. 220).

(b) Using two small screw drivers, lift the pressure plate and release it.

(c) Zero the dial indicator.

(d) Lift the pressure plate until it contacts the snap-ring and record the dial indicator reading.

Clearance should be 0.559 - 0.914 mm (0.022 - 0.036 in.). If clearance is incorrect, steel plates, discs, selective snap ring and pressure plates may have to be changed.

The selective snap ring thicknesses are:

  • .107-.109 in.
  • .098-.100 in.
  • .095-.097 in.
  • .083-.085 in.
  • .076-.078 in.
  • .071-.073 in.
  • .060-.062 in.

(16) Coat rear clutch thrust washer with petroleum jelly and install washer over input shaft and into clutch retainer (Fig. 221). Use enough petroleum jelly to hold washer in place.

(17) Set rear clutch aside for installation during final assembly.

Fig. 220 Checking Rear Clutch Pack Clearance Fig. 220 Checking Rear Clutch Pack Clearance

1 - DIAL INDICATOR

2 - PRESSURE PLATE

3 - SNAP RING

4 - STAND

5 - REAR CLUTCH

6 - GAUGE BAR

Fig. 221 Installing Rear Clutch Thrust Washer Fig. 221 Installing Rear Clutch Thrust Washer

1 - REAR CLUTCH RETAINER

2 - REAR CLUTCH THRUST WASHER

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    Dodge Durango Service Manual / Transmission and Transfer Case / Disassembly and assembly / Rear clutch

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