Forward Clutch

Forward Clutch:

DISASSEMBLY OF FORWARD CLUTCH




1. REMOVE THRUST BEARINGS AND RACES FROM BOTH SIDES OF CLUTCH
Note the position of the races.




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




4. COMPRESS PISTON RETURN SPRINGS AND REMOVE SNAP RING
a. Place SST on the spring retainer and compress the springs with a shop press.

SST 09350 - 32014 (09351 - 32070)

b. Remove the snap ring with snap ring pliers.

5. REMOVE SPRING RETAINER AND EIGHTEEN SPRINGS




6. BLOW OUT PISTON
Apply compressed air into oil passage to remove the piston. If the piston does not come out, use needle-nose pliers to remove it.

ASSEMBLY OF FORWARD CLUTCH




1. INSTALL NEW O-RINGS ON PISTON
Coal the O-ring with ATF.

2. INSTALL PISTON IN FORWARD CLUTCH DRUM
Press the piston into the drum with the cup side up, being careful not to damage the O-ring.




3. INSTALL EIGHTEEN PISTON RETURN SPRINGS, SPRING RETAINER 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 - 32014 (09351 - 32070)

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




5. INSTALL PLATES, DISCS AND FLANGE
Install in order: Plate-disc-plate-disc-plate- disc-plate-disc Install the flange with the flat end facing downward.

6. INSTALL OUTER SNAP RING
Check that the end gap of snap ring is not aligned with one of cutouts.







7. CHECK PISTON STROKE OF FORWARD CLUTCH
If replacing the disc, plate or flange, check the piston stroke.

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

SST 09350 - 32014 (09351 - 32190)

Piston stroke: 1.41 - 1.82 mm (0.0555 - 0.0717 in.)

If the piston stroke is less than the limit, parts may be misassembled and reinstall them.

If the piston stroke nonstandard, select another flange.

NOTE: There are two different thicknesses for the flange.

Flange thickness: 3.00 mm (0.1181 in.)
3.37 mm (0.1327 in.)




8. CHECK OPERATION OF FORWARD CLUTCH
Apply compressed air into the oil passage with the shaft and be sure that the piston moves.

If the piston does not move, disassemble and inspect.




9. INSTALL BEARING AND RACES

INSPECTION OF FORWARD CLUTCH




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




2. REPLACE OIL SEAL RINGS
a. Remove the oil seal rings.
b. Spread the rings apart and install them into the groove.

CAUTION: Do not spread the ring ends too much.

NOTE: After Installing the oil seal rings, check that they move smoothly.




3. INSPECT DISC. PLATE AND FLANGE
Check if the sliding surface of the discs, plates and flanges are worn or burnt. If necessary, replace them.

NOTE:
- If the lining of the disc is exfoliated or discolored, or even a part of the printed numbers are defaced, replace all discs.
- Before assembling new discs, soak them in ATF for at least two hours.