Forward Clutch

DISASSEMBLY





1. REMOVE FORWARD CLUTCH ASSEMBLY FROM DIRECT CLUTCH ASSEMBLY





2. PLACE FORWARD CLUTCH ONTO O/D SUPPORT
a. Place wooden blocks or equivalent to prevent forward clutch shaft from touching the work stand, and place the O/D support on them.
b. Place the forward clutch onto the O/D support.





3. CHECK PACK CLEARANCE OF FORWARD CLUTCH
Using SST and a dial indicator, measure the forward clutch piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
SST 09350-30020 (09350-06120)
Pack clearance: 0.4 - 0.8 mm (0.016 - 0.031 inch)
If the values are non-standard, inspect the discs.





4. REMOVE FLANGE, PLATE AND DISC
a. Using a screwdriver, remove the snap ring from the forward clutch drum.
b. Remove the flange, 6 plates and discs.





5. REMOVE CUSHION PLATE





6. REMOVE PISTON RETURN SPRING
a. Place SST on the spring retainer and compress the piston return spring with a press.
SST 09350-30020 (09350-07040)

NOTICE:
- Stop the press when the spring sheet is lowered to the place 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove, preventing the spring sheet from being deformed.
- Do not expand the snap ring excessively.

b. Using snap ring pliers, remove the snap ring.
c. Remove the piston return spring.





7. REMOVE FORWARD CLUTCH PISTON
a. Place the forward clutch drum onto the O/D support.
b. Hold the forward clutch piston by hand, apply compressed air to the O/D support to remove the forward clutch piston.
c. Remove the 2 O-rings from the piston.





8. REMOVE O-RING FROM FORWARD CLUTCH DRUM





9. REMOVE 3 OIL SEAL RINGS

INSPECTION





1. INSPECT DISC, PLATE AND FLANGE
Check to see if the sliding surfaces of the disc, plate and flange are worn or burnt. If necessary, replace them.

HINT:
- If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers is defaced, replace all discs.
- Before assembling new discs, soak them in ATF for at least 15 minutes.





2. CHECK FORWARD CLUTCH PISTON
a. Check that the check ball is free by shaking the piston.
b. Check that the valve does not leak by applying low-pressure compressed air.





3. 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 (0.9480 inch)
If the inside diameter is greater than the maximum, replace the forward clutch drum.

REASSEMBLY





1. INSTALL OIL SEAL RING
a. Coat the 3 oil seal rings with ATF.
b. Install the 3 oil seal rings to the forward clutch drum groove, then snug them down by squeezing their ends together.

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

HINT: After installing the oil seal rings, check that they rotate smoothly.

2. INSTALL NEW O-RING TO FORWARD CLUTCH DRUM
Coat a new O-ring with ATF and install it on the forward clutch drum.
3. INSTALL FORWARD CLUTCH PISTON





a. Coat new O-rings with ATF and install them on the forward clutch piston with a screwdriver.





b. Being careful not to damage the O-rings, press the clutch piston into the forward clutch drum with both hands.
4. INSTALL PISTON RETURN SPRING





a. Install the piston return spring.





b. Place SST on the spring retainer, and compress the return spring with a shop press.
SST 09350-30020 (09350-07040)

NOTICE:
- Stop the press when the spring sheet is lowered to the place 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove, preventing the spring sheet from being deformed.
- Do not expand the snap ring excessively.

c. Install the snap ring with snap ring pliers. Make sure the end gap of the snap ring is not aligned with the spring retainer claw.





5. INSTALL CUSHION PLATE WITH ITS ROUNDED END DOWN
6. INSTALL PLATE, DISC AND FLANGE





a. Install the 6 plates and discs.
Install in order: P = Plate D = Disc
P - D - P - D - P - D - P - D - P - D - P - D
b. And then install the flange with the rounded edge facing downward.

HINT: There are 8 different thicknesses for the flange.





Flange thickness:





c. Using a screwdriver, install the snap ring. Make sure the end gap of the snap ring is not aligned with the cutout portion of the forward clutch drum.





7. CHECK PACK CLEARANCE OF FORWARD CLUTCH
Using SST and a dial indicator, measure the forward clutch piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
SST 09350-30020 (09350-06120)
Pack clearance: 0.4 - 0.8 mm (0.016 - 0.031 inch)
If the values are non-standard, inspect the discs.





8. INSTALL DIRECT CLUTCH TO FORWARD CLUTCH
a. Make sure that the thrust washer is installed to the direct clutch drum.
b. Align the flukes of discs in the direct clutch.
c. Install the direct clutch onto the forward clutch.