Sun Shell
DISASSEMBLYSun Shell Assembly, Disassembled:
Removing Front Sun Shell:
1. Set assembly on overdrive drum.
2. Remove front sun shell.
No. 11 Needle Bearing:
3. Remove No. 11 needle bearing.
Intermediate Clutch Hub:
4. Remove intermediate clutch hub.
No. 10 Needle Bearing:
5. Remove No. 10 needle bearing.
Overdrive Drum And Transaxle Clutches:
6. Turn assembly onto intermediate cylinder hub.
7. Remove overdrive drum and one-way clutch assembly.
Overdrive Drum Components:
8. Remove low one-way clutch outer race, top cap, one-way clutch and bottom cap from overdrive drum.
No. 6 Thrust Washer:
9. Remove No. 6 thrust washer.
Forward Clutch Assembly Removal:
10. Remove forward clutch assembly by prying up on each side with two screwdrivers.
NOTE: Direct clutch hub O-ring seals retain forward clutch on hub. Pry evenly and do not locate screwdriver ends on or near forward clutch check ball.
Direct Clutch Hub O-rings:
11. Remove 0-rings from direct clutch hub.
Direct One-way Clutch Hub:
12. Remove direct one-way clutch and No. 7 thrust washer.
NOTE: Direct one-way clutch rotates clockwise when facing up.
Removing One-way Clutch And Race:
13. Remove one-way clutch race and one-way clutch.
ASSEMBLY
1. Set intermediate/direct cylinder on intermediate clutch cylinder side.
Direct One-way Clutch Hub:
2. Install No. 7 thrust washer into direct clutch being sure tabs are aligned with slots in direct clutch.
Removing One-way Clutch And Race:
3. Install one-way clutch with circular depressions facing upward.
Component Alignment:
4. Install direct one-way clutch and align onto clutch pack splines. Clutch rotates clockwise when facing up.
Installing O-rings:
5. Install two 0-ring seals.
6. Install forward clutch assembly. Use caution not to damage the 0-ring seals on direct clutch hub.
No. 6 Thrust Washer:
7. Install No. 6 thrust washer. Be sure oval pegs go into oval holes.
Assembling Overdrive Drum:
8. Install bottom cap, overdrive clutch with chamfer up, outer race and top cap.
Overdrive Drum And Transaxle Clutches:
9. Install overdrive drum and low one-way overrunning clutch assembly. Make sure overdrive drum is fully seated.
10. Turn assembly over and set on overdrive drum.
NOTE: One-way clutch outer race groove must be visible, if properly installed. Clutch outer race must turn counterclockwise.
Intermediate Clutch Hub:
11. Install No. 10 needle bearing onto intermediate clutch hub using petroleum jelly to hold in place.
12. Install intermediate clutch hub with No. 10 needle bearing. Make sure hub is fully seated.
No. 11 Needle Bearing:
13. Install No. 11 needle bearing with outer lip facing down.
Removing Front Sun Shell:
14. Install front sun and shell.