Front Clutch

DISASSEMBLY OF FRONT CLUTCH




1. REMOVE THRUST BEARING AND RACE FROM FRONT SIDE OF CLUTCH
Note the position of the races.




2. REMOVE SNAP RING FROM FRONT CLUTCH DRUM
3. REMOVE FRONT PLANETARY RING GEAR AND REAR CLUTCH HUB
4. REMOVE THRUST BEARING AND RACES
Note the position of the races.




5. REMOVE CLUTCH PLATE AND DISC
6. REMOVE THINNER SNAP RING




7. REMOVE REMAINING CLUTCH PLATES AND DISCS




8. COMPRESS PISTON RETURN SPRINGS AND REMOVE SNAP RING
Place SST on the spring seat and compress the springs with a shop press.
Using a screwdriver, remove the snap ring.
SST 09350-20013 (09369-20040)

9. REMOVE SPRING SEAT AND TWENTY SPRINGS




10. ASSEMBLE FRONT CLUTCH ON FRONT SUPPORT AND BLOW OUT PISTON
a. Slide the front clutch onto the front support.
b. Apply compressed air to the front support to remove the piston. If the piston does not come out completely, use pliers to remove it.
c. Remove the front clutch from the front support.

INSPECTION OF FRONT CLUTCH




1. INSPECT FRONT CLUTCH PISTON
a. Check that check ball is free by shaking the piston.
b. Check that valve does not leak by applying low pressure compressed air.

2. INSPECT DISC, PLATE, RETURN SPRING AND CLUTCH DRUM

NOTE: Do not allow the discs to dry Out.

Prepare new discs by soaking them at least two hours in ATF.

ASSEMBLY OF FRONT CLUTCH



1. INSTALL NEW O-RINGS ON PISTON

2. INSTALL PISTON IN FRONT CLUTCH DRUM
Press into the housing with the cup side up (check ball down).
Be careful not to damage the O-rings.




3. INSTALL TWENTY PISTON RETURN SPRINGS, SPRING SEAT AND SNAP RING IN PLACE

4. COMPRESS RETURN SPRINGS AND INSTALL SNAP RING IN GROOVE
a. Place SST on the spring retainer, and compress the springs with a shop press.
SST 09350-20013 (09369-20040)
b. Install the snap ring using a screwdriver.




5. INSTALL DISCS AND PLATES WITHOUT ASSEMBLING THINNER SNAP RING
Using low-pressure compressed air, (4 - 5 kg/sq.cm, 57 - 71 psi or 392 - 490 kPa) blow all excess ATF from the discs. For measurement of the clutch pack, install all plates and discs (temporarily without the thinner snap ring) in following order:
Cushion plate-plate-disc-plate-disc-plate-disc-plate




6. MEASURE CLEARANCE OF FRONT CLUTCH

Standard clearance: 0.30 - 1.49 mm (0.0118 - 0.0587 in.)

NOTE: Measure completely around the circumference.




7. INSTALL THINNER SNAP RING
Remove the snap ring, rear clutch hub and one plate and disc to allow installation of the thinner snap ring.




8. INSTALL INNER THRUST BEARING AND RACE

IMPORTANT: Coat the parts with petroleum jelly to keep them in place.
Install the inner race, and needle bearing. Press into place.

NOTE: Face the lip of the race toward the front clutch body.




9. INSTALL PLANETARY RING GEAR
Align the disc lugs with the hub teeth. Make sure the hub meshes with all discs and is fully inserted.




10. INSTALL REAR CLUTCH HUB AND OUTER SNAP RING
Check that the snap ring ends are not aligned with one of the cutouts.