Part 2

FRONT CLUTCH-A-904

Disassembly






Figure 18 shows a disassembled view of the front clutch assembly.
(1) Remove large waved snap ring that secures pressure plate in the clutch piston retainer. Lift pressure plate and clutch plates out of the retainer.






(2) Install compressor, Tool C-3575-A, over piston spring retainer (Fig. 19). Compress spring and remove snap ring, then slowly release tool until spring retainer is free of the hub. Remove tool, retainer, and spring.
(3) Invert clutch retainer assembly and bump it on a wood block to remove the piston. Remove seals from the piston and clutch retainer hub.

Inspection

Inspect plates and discs for flatness. They must not be warped or cone shaped.
Inspect facing material on all driving discs. Replace discs that are charred, glazed or heavily pitted. Discs should also be replaced if they show evidence of material flaking off or if facing material can be scraped off easily. Inspect driving disc splines for wear or other damage. Inspect steel plate and pressure plate surfaces for burning, scoring or damaged driving lugs. Replace if necessary.
Inspect steel plate lug grooves in clutch retainer for smooth surfaces, plates must travel freely in grooves. Inspect band contacting surface on clutch retainer for scores, the contact surface should be protected from damage during disassembly and handling. Note ball check in clutch retainer, make sure ball moves freely. Inspect piston seal surfaces in clutch retainer for nicks or deep scratches, light scratches will not interfere with sealing of seals. Inspect clutch retainer inner bore surface for wear from reaction shaft support seal rings. Inspect clutch retainer bushing for wear or scores.
Inspect inside bore of piston for score marks, if light, remove with crocus cloth. Inspect seal grooves for nicks and burrs. Inspect seals for deterioration, wear, and hardness. Inspect piston spring, retainer and snap ring for distortion.

Front Clutch Retainer Bushing Replacement-A-904






(1) Lay clutch retainer (open end down) on a clean smooth surface and place removing head Tool SP-3627 in the bushing (Fig. 20). Install handle Tool SP-3549 or C-4171 in removing head.
(2) Drive bushing straight down and out of clutch retainer bore. Be careful not to cock tool in the bore.
(3) Lay clutch retainer (open end up) on a clean smooth surface. Slide a new bushing on installing head Tool SP-3626, and start them in clutch retainer bore.
(4) Install handle in installing head. Drive bushing into clutch retainer until tool bottoms.
(5) Throughly clean clutch retainer before assembly and installation.

Assembly






(1) Lubricate and install inner seal on hub of clutch retainer. Make sure lip of seal faces down and is properly seated in the groove (Fig. 18).
(2) Install outer seal on the clutch piston, with lip of seal toward bottom of clutch retainer. Apply a coating of wax type lubricant or Door Ease to outer edge of seals and press seal to bottom of its groove around piston diameter for easier installation of piston assembly. Place piston assembly in retainer and carefully seat piston in bottom of retainer.






(3) Place spring on piston hub and position spring retainer and snap ring on the spring. Compress spring with Tool C-3575-A (Fig. 19), and seat snap ring in hub groove. Remove compressor tool.
(4) Lubricate all clutch plates, install one steel plate followed by a lined plate (disc) until the number given in specifications is installed. Install pressure plate and snap ring. Make sure snap ring is properly seated.






(5) Insert a feeler gauge between pressure plate and waved snap ring to measure maximum clearance here snap ring is waved away from pressure plate (Fig. 21). See Specifications" for allowed clearance. Specifications

FRONT CLUTCH-A-727

Disassembly






Figure 22 shows a disassembly view of the front clutch assembly
(1) Remove large waved snap ring that secures pressure plate in clutch piston retainer. Lift pressure plate and clutch plates out of the retainer. (Snap ring in 5 disc clutch is not waved.)






(2) Install compressor, Tool C-3863-A, over piston spring retainer (Fig. 23). Compress springs and remove snap ring, then slowly release tool until spring retainer is free of hub. Remove tool, retainer, and springs.
(3) Invert clutch retainer assembly and bump It on a wood block to remove piston. Remove seals from piston and clutch retainer hub.

Inspection

Inspect plates and discs for flatness. They must not be warped or cone shaped.
Inspect facing material on all driving discs. Replace discs that are charred, glazed or heavily pitted. Discs should also be replaced if they show evidence of material flaking off or if facing material can be scraped off easily. Inspect driving disc splines for wear or other damage. Inspect steel plate and pressure plate surfaces for burning, scoring or damaged driving lugs. Replace if necessary.
Inspect steel plate lug grooves in clutch retainer for smooth surfaces, plates must travel freely in the grooves. Inspect band contacting surface on clutch retainer for scores. Note ball check in clutch retainer, make sure ball moves freely. Inspect seal surfaces in clutch retainer for nicks or deep scratches; light scratches will not interfere with sealing of seals. Inspect clutch retainer bushing for wear or scores.
Inspect inside bore of piston for score marks, if light, remove with crocus cloth. Inspect seal grooves for nicks and burrs. Inspect rubber seals for deterioration, ware, and hardness. Inspect piston springs retainer and snap ring for distortion.


Front Clutch Retainer Bushing Replacement A-727






(1) Lay clutch retainer (open end down) on a clean smooth surface and place removing head Tool SP-3629 in the bushing. Install handle Tool SP-3549 or C-4171 in removing head (Fig. 24).
(2) Drive bushing straight down and out of clutch retainer bore. Be careful not to cock tool in the bore.
(3) Lay clutch retainer (open end up) on a clean smooth surface. Slide a new bushing on installing head Tool SP-5511, and start them in clutch retainer bore.
(4) Install handle in the installer. Drive bushing into clutch retainer until tool bottoms.
(5) Thoroughly clean clutch retainer before assembly and installation.

Assembly

(1) Lubricate and install inner seal on hub of clutch retainer. Make sure lip of seal faces down and is properly seated in the groove.
(2) Install outer seal on the clutch piston, with lip of seal toward bottom of clutch retainer. Apply a coating of wax type lubricant or Door Ease to outer edge of seals and press seal to bottom of its groove around piston diameter for easier installation of piston assembly. Place piston assembly in retainer and carefully seat piston in bottom of retainer.
















(3) Refer to "Specifications" and install proper number of springs on piston exactly as shown in Figure 25 or 26. Position spring retainer and snap ring over the springs. Compress springs with Tool C-3863-A (Fig. 23), and seat snap ring in hub groove. Remove compressor tool.
(4) Lubricate all clutch plates, install one steel plate followed by a lined plate (disc) until the number given in specifications is installed. Install pressure plate and snap ring. Make sure snap ring is properly seated.






(5) Insert a feeler gauge between pressure plate and waved snap ring to measure maximum clearance where snap ring is waved away from pressure plate (Fig. 21). See "Specifications" for allowed clearance.

REAR CLUTCH-A-904

Disassembly






Figure 27 shows a disassembled view of the rear clutch assembly.
(1) Remove large selective snap ring that secures pressure plate in clutch piston retainer. Lift pressure plate, clutch plates, and inner pressure plate out of the retainer.
(2) Carefully pry one end of wave spring out of its groove in clutch retainer, then remove wave spring, and clutch piston spring.
(3) Invert clutch piston retainer assembly and bump it on a wood block to remove piston. Remove seals from piston.
(4) If necessary, remove snap ring and press input shaft from piston retainer.

Inspection

Inspect facing material on all driving discs. Replace discs that are charred, glazed or heavily pitted. Discs should also be replaced if they show evidence of material flaking off or if facing material can be scraped off easily. Inspect driving disc splines for wear or other damage. Inspect steel plate and pressure plate surface for burning, scoring or damaged driving lugs. Replace if necessary. Inspect plates and discs for flatness, they must not be warped or cone-shaped.
Inspect steel plate lug grooves in clutch retainer for smooth surfaces, plates must travel freely in the grooves. Note ball check in clutch retainer, make sure ball moves freely. Inspect seal rings surfaces in clutch retainer for nicks or deep scratches; light scratches will not interfere with sealing of the seals. Inspect neoprene seal rings for deterioration, wear and hardness. Inspect piston spring and wave spring for distortion or breakage.






Inspect teflon and/or cast iron seal rings on input shaft for wear (Fig. 27). If required, replacement rings will be cast iron hooked joint type. Do not remove rings unless conditions warrant. Inspect rear clutch to front clutch #2 thrust washer for wear. Washer thickness should be .061 to .063 inch, replace if necessary.

Assembly

(1) If removed, press input shaft into piston retainer and install snap ring.
(2) Lubricate and install inner and outer seals on clutch piston. Make sure lip of seals face toward head of clutch retainer, and are properly seated in piston grooves (Fig. 27).
3) Place piston assembly in retainer and, with a twisting motion, seat piston in bottom of retainer.






(4) Place clutch piston spring on top of piston in clutch retainer. Start one end of wave spring in retainer groove (Fig. 28), then progressively push or tap spring into place making sure it is fully seated in the groove.
(5) Install inner pressure plate in clutch retainer with raised portion of plate resting on the spring.
(6) Lubricate all clutch plates, install one lined disc followed by a steel plate until all plates are installed. Install outer pressure plate and selective snap ring.






(7) Measure rear clutch plate clearance by having an assistant press down firmly on outer pressure plate, then insert a feeler gauge between the plate and snap ring (Fig. 29). See "Specifications" for allowed clearance. If necessary, install a new snap ring of proper thickness to obtain specified clearance. Low limit clearance is desirable. Rear clutch plate clearance is very important in obtaining proper clutch operation. Clearance can be adjusted by the use of various thickness outer snap rings. Snap rings are available in .060, .068 and .076 inch thickness.
(8) Grease cupped side of #3 thrust plate and install cupped side over input shaft.