Forward and Direct Clutch
Tools Required
- KM-698 Spring Compressor
Disassembly Procedure
WARNING: USE CAUTION WHEN REMOVING SNAP RINGS OR PERSONAL INJURY MAY RESULT.
1. Carefully remove the snap ring.
2. Remove the forward clutch pressure plate and the forward clutch disc pack.
Notice: Check the steel and friction plates for wear or damage. Replace as necessary.
Notice: New clutch plates should be soaked in TOTAL FLUID HX for two hours before being assembled.
3. Inspect the forward clutch steel and friction plates.
WARNING: USE CAUTION WHEN REMOVING SNAP RINGS OR PERSONAL INJURY MAY RESULT.
4. Carefully remove the snap ring.
5. Remove the direct clutch pressure plate and the direct clutch disc pack.
Notice: Check the steel and friction plates for wear or damage. Replace as necessary.
Notice: New clutch plates should be soaked in TOTAL FLUID HX for two hours before being assembled.
6. Inspect the direct clutch steel and friction plates.
7. Position spring compressor KM 698 on the clutch piston return spring. Using a press, compress the springs, then remove the snap ring from the groove.
8. Remove the snap ring and the clutch piston return spring.
WARNING: USE CAUTION WHEN REMOVING COMPONENTS WITH COMPRESSED AIR OR PERSONAL INJURY MAY RESULT.
Notice: If the piston does not come out completely, use needle nose pliers to remove.
9. Install the input shaft into the rear case. Apply 57 psi (396 kPa) of compressed air into the oil passage shown to remove the direct clutch piston.
10. Remove the direct clutch piston.
11. Remove and discard the direct clutch piston O-rings.
WARNING: USE CAUTION WHEN REMOVING COMPONENTS WITH COMPRESSED AIR OR PERSONAL INJURY MAY RESULT.
Notice: If the piston does not come out completely, use needle nose pliers to remove.
12. Install the input shaft into the rear case. Apply 57 psi (396 kPa) of compressed air into the oil passage shown to remove the forward clutch piston.
13. Remove the forward clutch piston.
14. Remove and discard the forward clutch piston O-rings.
WARNING: USE CAUTION WHEN CHECKING COMPONENTS WITH COMPRESSED AIR OR PERSONAL INJURY MAY RESULT.
15. Inspect the forward and direct clutch piston.
- Check that the valve does not leak by applying low-pressure compressed air.
16. Remove the seal ring.
Assembly Procedure
1. Clean the components using a clean, high-quality parts cleaning solvent and use compressed air to dry all parts. Inspect all parts for damage or wear.
2. Install new forward clutch piston O-rings.
Notice: Apply TOTAL FLUID HX to the new forward clutch piston O-rings and the input shaft seal area.
Notice: Seat the piston by pushing evenly around the circumference of the piston, being careful not to damage the outer seal.
3. Install the forward clutch piston.
4. Install new direct clutch piston O-rings.
Notice: Apply TOTAL FLUID HX to the new direct clutch piston O-rings and the input shaft seal area.
Notice: Seat the piston by pushing evenly around the circumference of the piston, being careful not to damage the outer seal.
5. Install the direct clutch piston.
6. Install the clutch piston return spring on the direct clutch piston.
7. Install the clutch piston return spring. Position spring compressor KM-698 on the clutch piston return spring. Using a press, compress the spring, then install the snap ring into the groove.
8. Install the direct clutch disc pack and direct clutch pressure plate.
- The installation order is: steel-friction-steel-friction-steel-friction-steel-friction-pressure plate.
9. Install the snap ring.
10. Install the forward clutch disc pack and forward clutch pressure plate.
- The installation order is: steel-friction-steel-friction-steel-friction-steel-friction-pressure plate.
11. Install the snap ring.
Notice: Apply TOTAL FLUID HX to the seal ring. Spread the seal ring apart and install it into the groove.
12. Install the seal ring.
WARNING: USE CAUTION WHEN CHECKING COMPONENTS WITH COMPRESSED AIR OR PERSONAL INJURY MAY RESULT.
13. Check the direct clutch operation.
- Install the forward and direct clutch assembly into the rear cover. Install a dial indicator.
- Apply 57 psi (396 kPa) of compressed air into the oil passage and measure the direct clutch piston stroke. The piston stroke is 0.059 - 0.074 inch (1.520 - 1.890 mm). The clutch should make a solid apply sound, with no whistle or sign of leaks.
WARNING: USE CAUTION WHEN CHECKING COMPONENTS WITH COMPRESSED AIR OR PERSONAL INJURY MAY RESULT.
14. Check the forward clutch operation.
- Install the forward and direct clutch assembly into the rear cover. Install a dial indicator.
- Apply 57 psi (396 kPa) of compressed air into the oil passage and measure the direct clutch piston stroke. The piston stroke is 0.059 - 0.074 inch (1.520 - 1.890 mm). The clutch should make a solid apply sound, with no whistle or sign of leaks.