Direct Clutch Assembly Disassemble

Direct Clutch Assembly Disassemble

Tools Required
* DT 46451 (DW240-020) Brake Clutch Spring Compressor
* DT 46453 (DW240-040) Direct Clutch Adapter





Notice: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice.

1. Install the direct clutch and thrust needle roller bearing on the oil pump.
2. Using a dial indicator, measure the direct clutch piston stroke while applying and releasing 392 kPa (57 psi) of compressed air.
If the stroke is non-standard, inspect the discs, the plates, and the flange.

The piston stroke is 0.4-0.8 mm (0.016-0.031 in).




3. Using the screwdriver, remove the snap ring.




4. Remove the flange (1), 2 discs (2), and 2 plates (3).




5. Place the DT 46451 (1) and DT 46453 (2) on the direct clutch return spring and compress.

Notice: Do not depress the direct clutch piston return spring lower than 1-2 mm (0.039-0.078 in.) beyond the snap ring groove. This will prevent the direct clutch piston return spring from becoming distorted.

Important: Do not expand the snap ring excessively.

6. Using a snap ring expander, remove the snap ring.




7. Remove the direct clutch return spring.




8. Install the direct clutch on the oil pump.

Notice: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice.

Important: Air pressure may cause the pistons to jump-out. When removing the piston, hold it with your hand using a waste cloth.

Important: Do not splash ATF when air-blowing.

9. Apply 392 kPa (57 psi) of compressed air to the oil pump to remove the direct clutch piston.
When the piston can not be removed as it is slanted, either blow the air again with the protruding side pushed or remove the piston using needle nose pliers with vinyl tape on the tip.




10. Using a small screwdriver, remove the O-ring (1) from the direct clutch piston.




11. Remove the O-ring (1) from the input shaft.





Important: Do not expand the ring ends excessively.

12. Remove the 2 seal rings (1) from the input shaft.