77733 11K IN
77733-11K-In 77733-11K-IN 77733-11K-IN 3072 instructions part uploads sonnax-dev
2014-11-20
: Sonnax 77733-11K-In 77733-11K-IN 1693 file instruction uploads
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PERFORMANCE H I GH PE R FOR MANCE TRANSMISSIO N PARTS Instructions GM 4L60-E, 4L65-E Smart-Tech Input Housing Kit with Heavy Duty Input Shaft ® Part No. 77733-11K • Smart-Tech® Input Housing with 300mm Non-Reluctor Style Input Shaft Assembly • PTFE Impregnated Rear Stator Support Bushing • Overrun Piston Inner Seal • Overrun Piston • 3-4 Clutch Apply Plate • 3-4 Clutch Return Springs (10) • Bolt-on Anchor Plate • Overrun Piston Outer Seal • Socket Head Cap Screws (15) Patent No. 8,857,592 NOTE: Fits 300mm non-reluctor units only. Also Available Forward Piston Installation Tool 77764-INSTL Verify Input Shaft Compatibility Verify input shaft compatibility by WARNING measuring (Figure 1). Sealing ring location should be the same as the original shaft for the application. Measure from face of ring gear (left) to radius at bottom of taper (right). Figure 2 A Use ‘91-Later Apply Ring Requires ‘91-later 3-4 apply ring stamped “7” with dimension "A" of 3.671 to 3.682" (Figure 2). Use ‘97-Later Ring Gear Requires ‘97-later ring gear. The correct spline length is 1.675" (Figure 3). Use Stamped Steel Forward Piston This kit must be used with a ‘97-later stamped steel forward piston (Figure 4). It cannot be used with aluminum forward piston or Sonnax billet forward piston 77764-01. Figure 3 Figure 1 Use Dual-Cage Return Spring This kit must be used with a '97-later dualcage return spring (24206085), identified by stamped retainer on both ends of the springs (Figure 5). Although not required, the ‘96-earlier style return spring is about 10% stronger and preferred for high RPM applications. To use the early-style return spring, swap the bottom spring retainer from a ‘97-later spring onto the ‘96-earlier spring. ©2014 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Figure 4 Steel Forward Piston Aluminum Forward Piston Figure 5 ‘97-Later Dual-Cage Return Spring ‘96-Earlier Return Spring 77733-11K-IN 11-20-14 Page 1 PERFORMANCE H I GH PE R FOR MANCE TRANSMISSIO N PARTS Instructions SMART-TECH ® INPUT HOUSING KIT WITH HEAVY DUTY INPUT SHAFT 77733-11K Figure 6 Overrun Piston Inner Seal Overrun Piston PTFE Impregnated Rear Stator Support Bushing Overrun Piston Outer Seal Input Shaft Input Drum Reinforcement Sleeve Modified Input Housing 3-4 Clutch Apply Plate Socket Head Cap Screws (15) Bolt-on Anchor Plate 3-4 Clutch Return Springs (10) 1. Clutch Selection This kit has approximately 5mm more room to allow for additional clutch combinations. The recommended combinations are: • Eight .067" frictions with seven .095" steels • Nine .062" frictions with eight .077" steels 2. 3-4 Clutch Pack Installation & Assembly Use normal assembly procedures for pistons, overrun clutches, forward clutches and input sprag. Sonnax forward piston installation tool 77764-INSTL is available to assist installing forward piston over installed reenforcement sleeve. NOTE: A lip seal is included for use with aftermarket gasket and seal kits that do not include this seal. a. Install the Sonnax apply plate, ensuring the five tabs securely fit over the OE 3-4 clutch apply ring. b. Install a friction plate against the face of the Sonnax apply plate. c. Install a steel plate against the friction plate. Continue alternating plates, ending with a friction plate on top. ©2014 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com 77733-11K-IN 11-20-14 Page 2 PERFORMANCE H I GH PE R FOR MANCE TRANSMISSIO N PARTS SMART-TECH ® INPUT HOUSING KIT WITH HEAVY DUTY INPUT SHAFT 77733-11K Figure 7 Instructions 2. 3-4 Clutch Pack Installation & Assembly (continued) d. With the clutch pack installed, measure the clearance from the top friction to the end face of the housing. Measure in multiple locations to ensure an accurate reading. Clearance should be between .050" and .060" (Figure 7). Adjust clearance by substituting different thickness steel plates. e. Install the 10 Sonnax 3-4 clutch return springs into the five OE spring retainers. These are required to keep the apply plate released and minimize drag from the clutches. f. Slide the spring retainers into the housing, with springs and retainers oriented as shown (Figure 8). g. Install the Sonnax bolt-on anchor plate onto input housing, aligning the bolt holes with the threaded holes in the input housing. Figure 8 h. To ensure the correct torque spec and thread locking, all threads should be clean and dry prior to assembly. Apply a drop of Loctite® Threadlocker 262 or similar product to the threads of each socket head cap screw. Install all screws through the backing plate into the threaded housing and lightly tighten each screw. Orient the spring retainer as shown, with the free part of the spring facing out and the retainer towards the O.D. of the housing. Figure 9 Overrun Feed 3-4 Feed i. Torque each fastener to 51 in-lb. Work around the housing in a crisscross (star) pattern to ensure even pressure on the backing plate. 3. Final Verification Step Air test assembled housing (Figure 9). 4. PTFE Bushing Installation a. Remove rear stator bushing, taking care not to damage bushing bore. Forward Feed b. Install Sonnax PTFE-coated bushing using appropriate driver tool. Minimal Leaks ©2014 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com 77733-11K-IN 11-20-14 Page 3
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