Direct Clutch

COMPONENTS





DISASSEMBLY OF DIRECT CLUTCH



1. REMOVE DIRECT CLUTCH DRUM ASSEMBLY FROM FORWARD CLUTCH ASSEMBLY




2. REMOVE CLUTCH DRUM THRUST WASHER FROM DIRECT CLUTCH ASSEMBLY




3. REMOVE SNAP RING FROM CLUTCH DRUM
4. REMOVE FLANGE, FOUR DISCS AND FOUR PLATES




5. COMPRESS PISTON RETURN SPRING AND REMOVE SNAP RING
Place SST on the spring retainer and compress the return spring with a shop press. Using snap ring pliers, remove the snap ring.
SST 09350 - 30020 (09350 - 07040)

6. REMOVE PISTON RETURN SPRING




7. REMOVE DIRECT CLUTCH PISTON
a. Place the direct clutch drum onto the OD support.
b. Hold the direct clutch piston by hand, apply compressed air to the OD support to remove the direct clutch piston.
c. Remove the direct clutch piston.

8. REMOVE THE TWO O-RINGS FROM PISTON

INSPECTION OF DIRECT CLUTCH




1. INSPECT DISC, PLATE AND FLANGE
Check that the sliding surface of disc is not worn or burnt. If the disc is worn or burnt, replace all discs. Then check that the sliding surfaces of plate and flange are not worn or burnt. If necessary, replace them.




2. CHECK DIRECT CLUTCH PISTON
a. Check that check ball is free by shaking the piston.
b. Check that the valve does not leak by applying low-pressure compressed air.




3. CHECK DIRECT CLUTCH DRUM BUSHING
Using a dial indicator, measure the inside diameter of the clutch drum bushing.

Maximum inside diameter: 53.99 mm (2.1256 in.)

If the inside diameter is greater than the maximum, replace the clutch drum.

ASSEMBLY OF DIRECT CLUTCH
1. INSTALL NEW O-RINGS ON DIRECT CLUTCH PISTON
Coat new O-rings with ATF and install them on the direct clutch piston.




2. INSTALL DIRECT CLUTCH PISTON TO DIRECT CLUTCH DRUM
Being careful not to damage the O-rings, press in the direct clutch piston into the clutch drum by both hands.




3. INSTALL PISTON RETURN SPRING




4. COMPRESS PISTON RETURN SPRING AND INSTALL SNAP RING IN GROOVE
a. Place SST on the spring retainer, and compress the return spring with a shop press.
SST 09350 - 30020 (09350 - 07040)

b. Install the snap ring with snap ring pliers. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.




5. INSTALL PLATES AND DISCS
Install in order: P-D-P-D-P-D-P-D




6. INSTALL FLANGE
Install the flange, facing the flat end downward.




7. INSTALL SNAP RING
Install the snap ring with a screwdriver. Be sure the end gap of the snap ring is not aligned with the cutout portion of the direct clutch drum.

8. CHECK PISTON STROKE OF DIRECT CLUTCH (C(2))



a. Place the direct clutch assembly onto the OD support assembly.




b. Using a dial indicator, measure the direct clutch piston stroke applying and releasing the compressed air (4 - 8 kg/sq.cm, 57 - 114 psi or 392 - 785 kPa) as shown.

Piston stroke: 1.37- 1.67 mm (0.0539 - 0.0657 in.)

If the piston stroke is less than the limit, parts may be mis-assembled.
If the piston stroke is nonstandard, select another flange.




NOTE: There are eight flanges.




9. INSTALL CLUTCH DRUM THRUST WASHER
Coat the thrust washer with petroleum jelly and install it onto the direct clutch.

NOTE: Make sure that the lugs shape match the cutout portions on the direct clutch.

10. INSTALL DIRECT CLUTCH ASSEMBLY TO FORWARD CLUTCH ASSEMBLY




a. Align the flukes of discs in the direct clutch.
b. Install the direct clutch assembly onto the forward clutch assembly.




c. Check that the distance from the direct clutch end to the forward clutch end should be 71.2 mm (2.803 in.).