FOR THE DIRECT CLUTCH: Build the clutch pack by
alternating between the OEM thickness steels (.078") and the furnished thicker steels
(.090"). Install top backing plate and snap ring. Air-check the direct clutch several
times to seat all components. Insert a feeler gauge between the top of the backing plate
and the bottom of the snap ring or between the bottom of the backing plate and the top
friction plate, whichever is more convenient. The desired clearance is .020" -
.025". Alternate between the OEM sized steels and the furnished thicker steels until
the clearance is achieved.
FOR THE COAST CLUTCH: Build the clutch pack with the
OEM thickness steel and friction plates. Install the top backing plate. Install the
furnished top backing plate snap ring. Air-check the coast clutch several times to seat
all components. Insert a feeler gauge between the bottom of the backing plate and the top
friction plate. The desired clearance is .015" - .025". Some clutch pack
clearances may be slightly tighter than .015". This is acceptable providing there is
an absolute minimum of .010" clearance. If the clutch clearance is tighter than
.010", then reinstall the originally removed snap ring.
Our continuing field testing of the E4OD Delayed Reverse Fix Kit™
has found that in some applications, a double apply (bump-bump) can be experienced during
the initial reverse engagement. In order to have this kit perform properly, you must
reduce the clutch clearances in the Reverse, Direct, and Coast Clutch Packs. Failure to
reduce ALL THREE clutch packs can often result in a double or even triple apply feel
during the initial reverse engagement. This repair kit significantly reduces the reverse
engagement time duration by reducing the amount of clutch fill volume to the bare
essentials of what is actually needed for reverse apply. However, even with this clutch
fill volume reduction, do not expect an instant reverse engagement. During reverse apply,
three friction element circuits are slowly filling simultaneously along with the direct
clutch accumulator system and the 4-3-2 manual timing valve circuit which also acts as an
accumulator.
Simply stated, the E4OD is a "thirsty" unit in terms of
reverse apply clutch fill volume. When the E4OD transmission is functioning properly, you
will find the total engagement time, from the moment the selector is moved to FULL reverse
engagement, will average 1.42 seconds with this kit installed. If you find the total
engagement time exceeds 2.5 seconds WITH this kit installed, suspect
valve body and/or case warp, loose valve body and/or accumulator body bolts, or loose
and/or stripped bolts for the hold down support plate located near the reverse clutch feed
hole. Rebuilder’s Question: "Some technical advisories have
said that by installing an orifice into the reverse clutch feed hole, it will help to fix
a double apply feel. Can this be done with the Alto kit?" Answer:
Yes. Installing a cup plug with a .100" drilled orifice will allow the reverse clutch
to apply with better coordination when the direct and coast clutch applies. Just be sure
to use a cup plug that properly fits the case feed hole and also ensure that the size of
the orifice is drilled to .096" - .101". A hole below .090" can CAUSE a
double apply feel.
