Disassembly

1. Remove direct clutch from forward clutch.





2. Remove clutch drum thrust washer.
3. Check clutch piston stroke length as outlined in following steps.





4. Mount direct clutch on overdrive support assembly.
5. Mount dial indicator on clutch and position indicator plunger on clutch piston.





6. Apply 57 - 114 psi air pressure through feed hole in overdrive support and note piston stroke length. Check stroke at least twice.
7. Piston stroke length should be 1.37 mm - 1.67 mm (0.054 - 0.065 inch). If stroke length is incorrect, either the clutch pack retainer or clutch discs will have to be replaced.





8. Remove clutch pack snap ring and remove retainer and clutch pack from drum.





9. Compress clutch piston return springs with tool 7538, or equivalent and remove clutch piston snap ring.
10. Remove compressor tool and return spring.





11. Remove clutch piston. Remount clutch on overdrive support. Apply compressed air through piston feed hole in support to remove piston. Use only enough air to ease piston nut.
12. Remove and discard clutch piston O-rings.
13. Measure clutch disc thickness. Minimum allowable thickness is 1.84 mm (0.0724 inch). Replace clutch pack if any disc is below minimum thickness.





14. Measure free length of piston return springs with springs in retainer. Length should be 21.32 mm (0.839 inch). Replace return springs if not within specification.





15. Check clutch piston check ball. Shake piston to see if ball moves freely. Then check ball seating by applying low pressure compressed air to ball inlet as shown. Air should not leak past check ball.
16. Measure inside diameter of clutch drum bushing. Inside diameter should be no more than 53.97 mm (2.1248 inch). Replace drum if bushing inside diameter is greater than specified.