FORWARD CLUTCH DISASSEMBLY/ASSEMBLY

id051300262300

Forward Clutch Component

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1
Retaining ring (select fit)
2
Forward clutch pressure plate
3
Forward clutch internal spline plate (friction)
4
Forward clutch external spline plate (steel)
5
Retaining ring
6
Forward clutch piston spring component
7
Forward clutch piston
8
Forward clutch cylinder


Disassembly

1.  Remove the pressure plate.

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(1)  Remove the retaining ring.
(2)  Remove the pressure plate.

2.  Remove the forward clutch disc pack.

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•  Inspect the forward clutch plates for wear, damage or overheating.

Warning
•  Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions may result in personal injury.
Caution
•  Do not fully depress the SST or damage to the spring retainer may occur.

3.  Using the SST, remove the retaining ring.

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4.  Relieve the forward clutch spring tension and remove the tool.

5.  Remove the forward clutch piston spring component.

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Warning
•  Air pressure must not exceed 138 kPa {1.4 kgf·m, 20 psi}. Wear safety glasses when using compressed air. Make sure the cylinder is facing down as shown. Failure to follow these instructions may result in personal injury.

6.  Remove the forward clutch piston.

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(1)  Place the forward clutch cylinder with forward clutch piston facing down.
(2)  Install the center support on the forward clutch cylinder.
(3)  Apply air pressure to the left port of the center support.


Assembly

1.  Inspect the clutch components for damage or wear. Install new components as necessary.

•  Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
•  Inspect the clutch plates for damage.
•  Inspect the clutch piston springs.
•  Inspect the needle bearing and seal rings for damage.
•  Check clutch hub thrust surfaces for damage.
•  Check clutch plates for flatness and fit on the clutch hub serrations.

2.  Inspect the forward clutch piston and seals.

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Note
•  If the seals on the forward clutch piston show any signs of damage, a new forward clutch piston will need to be installed.

3.  Inspect the forward clutch drum component.

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(1)  Inspect the forward clutch cylinder surfaces for scores or burrs.
(2)  Inspect the forward clutch piston for scores or burrs.
(3)  Verify the check ball is free to move in the piston.

Caution
•  Care must be taken to prevent damage to the seals.
Note
•  Lubricate the forward clutch piston inner and outer seal with clean ATF.

4.  Install the forward clutch piston component into the forward clutch cylinder.

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5.  Install the forward clutch piston spring component.

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Caution
•  Do not fully depress the clutch piston spring compressor or damage to the spring retainer may occur.

6.  Using the SST, install the spring retaining ring.

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Caution
•  The forward clutch friction plates are directional and must be installed with grooves pointing counterclockwise.
•  If new plates are used, they should be soaked in clean ATF before assembly.

7.  If reusing plates, grooves must be installed counterclockwise. Install the direct clutch disc pack.

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8.  Install the steel clutch plates and friction clutch plates in alternating order starting with a steel clutch plate.

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Caution
•  The retaining ring is a select fit.

9.  Install the original selective retaining ring.

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(1)  Install the forward clutch pressure plate.
(2)  Install the original selective retaining ring.

Warning
•  Air pressure must not exceed 138 kPa {1.4 kgf/cm2, 20 psi}. Wear safety glasses when using compressed air. Make sure the cylinder is facing down as shown. Failure to follow these instructions may result in personal injury.

10.  Air check the forward clutch piston.

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(1)  Place the forward clutch cylinder with forward clutch piston facing down.
(2)  Install the transmission center support on the forward clutch cylinder.
(3)  Apply air pressure to the left port of the center support.

11.  Check the forward clutch disc pack free play.

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(1)  Press down on the forward clutch disc pack.
(2)  Using a feeler gauge, check the gap between the forward clutch retaining ring and the forward clutch pressure plate.
•  If the clearance is not within specifications, install the correct size retaining ring.
Forward clutch clearance
Standard: 1.3—2.0 mm {0.051—0.079 in}

Retaining ring size for forward clutch clearance

Thickness

Diameter

mm

in

mm

in
1.73
0.0681
141.45
5.65
2.08
0.0819
141.45
5.65
2.44
0.0961
141.45
5.65