Forward Clutch

COMPONENTS





DISASSEMBLY OF FORWARD CLUTCH



1. REMOVE FORWARD CLUTCH ASSEMBLY FROM DIRECT CLUTCH ASSEMBLY




2. REMOVE BEARING AND RACE
a. Place wooden blocks, etc. to prevent forward clutch shaft from touching the work stand, and place the OD support on them.
b. Place the forward clutch onto the OD support and remove the bearing and race.




3. REMOVE SNAP RING FROM CLUTCH DRUM
4. REMOVE FLANGE, DISCS AND PLATES

7M-GE: One flange, five discs and five plates
7M-GTE: One flange, six discs and six plates




5. REMOVE CUSHION PLATE




6. COMPRESS PISTON RETURN SPRING AND REMOVE SNAP RING
Place SST on the spring retainer and compress the return spring with a shop press. Using snap ring pliers, remove the snap ring.
SST 09350 - 30020 (09350 - 07040)

7. REMOVE PISTON RETURN SPRING




8. REMOVE FORWARD CLUTCH PISTON
a. Place the forward clutch drum onto the OD support.
b. Hold the forward clutch piston by hand, apply compressed air to the OD support to remove the forward clutch piston.
c. Remove the forward clutch piston.

9. REMOVE THE TWO O-RINGS FROM PISTON




10. REMOVE O-RING FROM FORWARD CLUTCH DRUM




11. REMOVE THE THREE OIL SEAL RINGS




12. REMOVE ASSEMBLED BEARING AND RACE


INSPECTION OF FORWARD CLUTCH



1. INSPECT DISC, PLATE AND FLANGE
Check that the sliding surface of disc is not worn or burnt. If the disc is worn or burnt, replace all discs.
Then check that the sliding surfaces of plate and flange are not worn or burnt.
If necessary, replace them.




2. CHECK FORWARD CLUTCH PISTON
a. Check that 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 in.)

If the inside diameter is greater than the maximum, replace the forward clutch drum.


ASSEMBLY OF FORWARD CLUTCH



1. INSTALL ASSEMBLED BEARING AND RACE
Coat the assembled bearing and race with petroleum jelly and install it onto the forward clutch drum, facing the race side downward.

NOTE: Assembled bearing and race diameter
Inside diameter: 33.7 mm (1.327 in.)
Outside diameter: 47.6 mm (1.874 in.)




2. INSTALL THE THREE OIL SEAL RINGS
a. Coat the three oil seal rings with ATF.
b. Contract the oil seal rings as shown, and install them onto the forward clutch drum.

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

NOTE: After installing the oil seal rings, check that they move smoothly.




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

4. INSTALL NEW O-RINGS TO FORWARD CLUTCH PISTON
Coat new O-rings with ATF and install them on the forward clutch piston.




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




6. INSTALL PISTON RETURN SPRING




7. COMPRESS PISTON RETURN SPRING AND INSTALL SNAP RING IN GROOVE
a. Place SST on the spring retainer, and compress the return spring with a shop press.
SST 09350 - 30020 (09350 - 07040)

b. 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 END DOWN AS SHOWN




9. INSTALL DISCS, PLATES AND FLANGE
a. Install in order:

7M-GE: P-D-P-D-P-D-P-D-P-D
7M-GTE: P-D-P-D-P-D-P-D-P-D-P-D

b. And then install the flange, facing the rounded edge downward.




10. INSTALL SNAP RING
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.




11. CHECK PISTON STROKE OF FORWARD CLUTCH (C(1))
Using a dial indicator, measure the forward clutch piston stroke applying and releasing the compressed air (4 - 8 kg/sq.cm, 57 - 114 psi or 392 - 785 kPa) as shown.

Piston stroke:
7M-GE: 3.42 - 4.23 mm (0.1346 - 0.1665 in.)
7M-GTE: 3.73 - 4.59 mm (0.1469 - 0.1807 in.)

If the piston stroke is not within specification, replace the discs, and recheck the piston stroke.




12. INSTALL RACE AND BEARING
Coat the race and bearing with petroleum jelly, and install them onto the forward clutch drum.




NOTE: Race and bearing diameter

13. INSTALL DIRECT CLUTCH ASSEMBLY TO FORWARD CLUTCH ASSEMBLY



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




c. Check that the distance from the direct clutch end to the forward clutch end should be 71.2 mm (2.803 in.).