Direct Clutch Assembly (C-2)

Direct Clutch Assembly (C-2)





Disassembled View

Disassembly





Remove direct clutch drum assembly from forward clutch assembly.





1. Check piston stroke of direct clutch (C-2).
Place the direct clutch assembly onto the OD support assembly.





Using a dial indicator, measure the direct clutch piston stroke by applying and releasing compressed air (390 - 780 kPa or 57 - 114 psi).
Pack clearance: 0.4 - 0.7 mm (0.016 - 0.028 inch)
2. Remove the clutch drum thrust washer (Plastic) from the rear end of direct clutch.
3. Remove the snap ring from the direct clutch drum.
4. Remove the flange, plates and discs.





5. Place special tool on the spring retainer and compress the return spring.
Using snap ring pliers, remove the snap ring.
Spring compressor: J-25048
6. Remove the piston return spring.





7. Place the direct clutch drum onto the OD support.
Holding the direct clutch piston by hand, apply compressed air to the OD support to remove the direct clutch piston.
Remove the direct clutch piston from direct clutch drum.
8. Remove two O-rings from piston.

Inspection and Repair





1. Check piston return spring.
Using calipers, measure the free length of the return spring.
Standard length: 21.3 mm (0.839 inch)





2. Check discs.
Using micrometer, measure the thickness of the discs.
Minimum thickness: 2.04 mm (0.0803 inch)
If the thickness is less than the minimum, replace the disc.





3. Check direct clutch piston.
Check that check ball is free by shaking the piston.
Check that the valve does not leak by applying low-pressure compressed air.





4. Check direct clutch drum bushing.
Using a dial indicator, measure the inside diameter of the clutch drum bushing.
Maximum inside diameter: 53.99 mm (2.1256 inch)
If the inside diameter is greater than the maximum, replace the clutch drum.

Reassembly
1. Coat new O-rings with ATF and install them on the direct clutch piston.





2. Install direct clutch piston to direct clutch drum.
Being careful not to damage the O-rings, press in the direct clutch piston into the clutch drum, using both hands.





3. Install piston return spring.





4. Compress piston return spring and install snap ring in groove.
^ Place special tool on the spring retainer, and compress the return spring.
^ Install the snap ring with snap ring pliers.
^ Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
Spring compressor: J-25048





5. Install four plates and four discs.
Install in order: P-D-P-D-P-D-P-D
P: Plate, D: Disc





6. Install the flange, with the flat side facing downward.





7. Install the snap ring with a screwdriver.
Be sure the end gap of the snap ring is not aligned with the cutout portion of the direct clutch drum.





8. Check piston stroke of direct clutch (C-2).
Place the direct clutch assembly onto the OD support assembly.





Using a dial indicator, measure the direct clutch piston stroke by applying and releasing compressed air (390 - 780 kPa or 57 - 114 psi) as shown.
Pack clearance: 0.4 - 0.7 mm (0.016 - 0.028 inch)
If the piston stroke is not within specification, replace the discs and recheck the piston stroke.
If the piston stroke is nonstandard, select another flange.





Flange sizes





9. Coat the clutch drum thrust washer (plastic) with petroleum jelly and install it onto the direct clutch.

NOTE: Make sure that the lugs fit into the cutout portions on the direct clutch.

Align the flukes of discs in the direct clutch.
Install the direct clutch assembly onto the forward clutch assembly.





Check that the distance from the direct clutch end to the forward clutch end is 71.2 mm (2.803 inch).