Forward Clutch Disassemble & Service

Forward Clutch

Clutch Disassembly

Special Tools Required
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A
^ Clutch spring compressor attachment 07LAE-PX40100 or 07HAE-PL50101

1. Remove the snap ring (A), then remove the clutch end-plate, the clutch discs, and the plates with a screwdriver (B).





2. Remove the wave spring.





3. Install the special tool on the clutch assembly.





4. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the clutch.





5. If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.





6. Compress the spring until the snap ring can be removed.





7. Remove the snap ring (A). Then remove the special tools (B), spring retainer (C), and return spring.





8. Wrap a shop rag around the clutch drum (A), and apply air pressure to the fluid passage to remove the piston (B). Place a finger tip on the other end while applying air pressure.





Clutch Reassembly

Special Tools Required
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A
^ Clutch spring compressor attachment 07LAE-PX40100 or 07HAE-PL50101
^ Clutch compressor attachment 07ZAE-PRP0100

1. Inspect the clutch piston (A) and clutch piston check valve (B). If the clutch check valve is loose or damaged, replace the clutch piston.





2. Check the spring retainer (C) for wear and damage.
3. Inspect the clutch discs (D), clutch plates (E), and clutch end-plate (F) for wear, damage, and discoloration.
^ If the clutch discs are worn or damaged, replace the discs as a set.
^ If the clutch plates are worn, damaged, or discolored, replace the plates as a set.
^ If the clutch end-plate is worn, damaged, or discolored, inspect the clutch end-plate-to-top disc clearance, then replace the clutch end-plate.

4. Soak the clutch discs thoroughly in CVTF for a minimum of 30 minutes.
5. Install new O-rings (A) on the clutch piston (B).





6. Install the piston (A) in the clutch drum (B). Apply pressure and rotate to ensure proper seating. Lubricate the piston O-ring with CVTF before installing. Do not pinch the O-ring by installing the piston with excessive force.





7. Install the return spring (A) and spring retainer (B), and position the snap ring (C) on the retainer.





8. Install the special tool.





9. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the clutch.





10. If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.





11. Compress the return spring.





12. Install the snap ring (A).





13. Remove the special tool.
14. Install the wave spring.





15. Starting with a clutch plate, alternately install the clutch plates and discs. Install the clutch end-plate (A) with the flat side toward the disc (B).





16. Install the snap ring (A) with a screwdriver (B).





17. Verify that the snap ring end gap (A) is 7.9 mm (0.311 in.) or more.





18. Check that the clutch piston engages by applying air pressure to the fluid passage, and also check that the piston releases when air pressure is released.
19. Set a dial indicator (A) on the clutch end-plate (B).





20. Zero the dial indicator with the clutch end-plate lifted up to the snap ring (C).
21. Release the clutch end-plate to lower the clutch end-plate, then put the special tool on the end-plate (A).





22. Press the special tool down with 39 N (4 kgf, 9 lbf) using a force gauge, and read the dial indicator (B). The dial indicator reads the clearance (C) between the clutch end-plate and top disc (D). Take measurements in at least three places, and use the average as the actual clearance.

Clutch End-Plate-to-Top Disc Clearance
Service Limit: 0.6 - 0.8 mm (0.024 - 0.031 in.)

23. If the clearance is out of service limit, select a new clutch end-plate from the following table.





FORWARD CLUTCH END-PLATE





24. Install the new clutch end-plate, then recheck the clearance. If the thickest clutch end-plate is installed, but the clearance is still over the service limit, replace the clutch discs and plates.