Forward Clutch Assembly (C-1)

Forward Clutch Assembly (C-1)





Disassembled View

Disassembly





Remove forward clutch assembly from direct clutch assembly.





1. Place wooden blocks, etc. to prevent forward clutch shaft from touching the work stand, and place the OD support on them.
Place the forward clutch onto the OD support and remove the bearing and race.





2. Check piston stroke of forward clutch (C-1).
Using a dial indicator, measure the forward clutch piston stroke by applying and releasing compressed air (390 - 780 kPa or 57 - 114 psi) as shown.
Pack clearance: 0.5 - 0.9 mm (0.020 - 0.035 inch)





3. Remove snap ring from clutch drum.
4. Remove the flange, disc and plate, and cushion plate.





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 forward clutch drum onto the OD support. Holding the forward clutch piston by hand, apply compressed air to the OD support to remove the forward clutch piston.
8. Remove the O-rings from piston.
9. Remove the O-ring from forward clutch drum.
10. Remove the oil seal rings and thrust bearing from forward clutch drum.

Inspection and Repair





1. Check forward 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.





2. Check forward clutch drum bushing.
Using a dial indicator, measure the inside diameter of the forward clutch drum bushing.
Maximum inside diameter: 24.08 mm (0.948 inch)
If the inside diameter is greater then the maximum, replace the forward clutch drum.





3. Check disc, plate and flange.
Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them.
^ If the lining of the disc is peeling off or discolored, or even if parts of the printed numbers are defaced, replace all discs.
^ Before assembling new discs, soak them in ATF for at least fifteen minutes.





4. Check piston return spring.
Using calipers, measure the free length of the return spring.
Standard length: 19.47 mm (0.7665 inch)

Reassembly





1. Coat the assembled thrust bearing and race with petroleum jelly and install it onto the forward clutch drum, with the race side facing downward.





Bearing and race (Reference)





2. Coat the three oil rings with ATF.
Contract the oil seal rings as shown, and install three oil seal rings onto the forward clutch drum.

NOTE: Do not spread the ring ends more than necessary.





3. Coat a new O-ring with ATF and install O-ring on the forward clutch drum.
4. Coat new O-rings with ATF and install two O-rings on the forward clutch piston.





5. Being careful not to damage the O-rings, press the forward clutch piston into the forward clutch drum.





6. Install piston return spring.





7. Place special tool on the spring retainer, and compress the return spring.
Spring compressor: J-25048
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.





8. Install cushion plate rounded side down as shown.
9. Install six discs and six plates.
Install in order: P-D-P-D-P-D-P-D-P-D-P-D





10. And then install the flange, with the rounded edge facing downward.





11. 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 forward clutch drum.





12. Check piston stroke of forward clutch (C-1).
Using a dial indicator, measure the forward clutch piston stroke by applying and releasing the compressed air (380 - 780 kPa or 57 - 114 psi) as shown.
Pack clearance: 0.5 - 0.9 mm (0.020 - 0.035 inch)
If the piston stroke is not within specification, replace the discs, and recheck the piston stroke.





Available flange sizes





13. Coat the race and thrust bearing with petroleum jelly, and install them onto the forward clutch drum.





Race and bearing diameter (Reference)





14. 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).