Forward Clutch

Special Tools:

Disassembly

1. CAUTION: The retaining ring is a select fit. See assembly procedure if the ring or clutch plate pack is replaced.

Remove the forward clutch pressure plate.
1. Remove the forward clutch retaining ring.
2 Remove the forward clutch pressure plate.

2. CAUTION: If new plates are being used, they should be soaked in clean transmission fluid for at least 30 minutes before assembly.

CAUTION: Clutch discs are directional. Note direction of grooves for installation.

Remove the forward clutch disc pack.
- Inspect the forward clutch plates for wear, damage or overheating.

3. 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 Clutch Spring Compressor or damage to the spring retainer may occur.

Use Clutch Spring Compressor to remove the forward clutch piston retaining ring.
1. Install the Clutch Spring Compressor.
2. Compress the forward clutch piston springs.
3. Remove the forward clutch piston spring retaining ring.
4. Relieve the forward clutch spring tension and remove the Clutch Spring Compressor.

5. Remove the forward clutch piston spring retainer and 15 forward clutch piston springs.
1. Remove the forward clutch piston spring retainer.
2. Remove the 15 forward clutch piston springs.
- Inspect the forward clutch piston springs for d1stortion.

6. WARNING: Air pressure must not exceed 138 kPa (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.

Remove the forward clutch piston.
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.

7. Remove and discard the forward clutch piston seals.
1. Remove the forward clutch piston outer seal and inspect the forward clutch piston for cracks.
2. Remove forward clutch cushion spring.
3. Remove the forward clutch piston inner seal.

8. Inspect the remaining forward clutch drum components for damage or wear, replace components as necessary:
1. Inspect the forward clutch cylinder surfaces for scores or burrs. Minor scores or burrs may be removed with a crocus cloth. Replace the forward clutch cylinder if it is badly scored or damaged.
2. Inspect forward clutch piston for scores or burrs. Minor scores or burrs may be removed with a crocus cloth. Replace forward clutch cylinder if it is badly scored or damaged.
3. Make sure the check ball is free and clear of debris, has freedom of movement, and is properly seated.
9. Inspect the forward clutch drum components.
- Inspect clutch plate serration for scores or burrs.
- Inspect fluid passages for obstructions. Clean out all passages.
- Inspect the friction clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surface. Replace all parts that are deeply scored.
- Check clutch plates for flatness and fit on the clutch hub serrations. Discard any plate that does not slide freely on the serrations or that is not flat.
- Check clutch hub thrust surfaces for scores and clutch hub splines for wear.
- Inspect for damage or wear to the clutch disc grooves and retaining ring grooves.

10. Note: Inspect the needle bearing for damage and install new if necessary.

Inspect the needle bearing for damage.

11. CAUTION: Do not overtighten the tool or damage to the forward clutch bearing may occur

Note: This step only needs to be carried out if there is damage to the bearing.

Using the special tools, remove the forward clutch bearing.

12. Note: This step only needs to be carried out if there is damage to the bearing.

Inspect the forward clutch outer race for scoring or nicks, if any damage is found the forward clutch drum will need to be replaced.

Assembly

1. Thoroughly clean all parts in solvent and blow dry with mo1sture free compressed air.

2. Note: This step only needs to be carried out if the bearing was removed.

Clean and lubricate the outer surface with clean transmission fluid.

3. Note: This step only needs to be carried out if the bearing was removed.

Note: The rectangular hole in the inside of the forward clutch bearing must face up (away from the forward clutch drum)

Install the forward clutch bearing with the rectangular hole facing up.

4. Note: This step only needs to be carried out if the bearing was removed.

Using the special tools, install the forward clutch bearing.

5. Note: This step only needs to be carried out if the bearing was removed.

Inspect that the bearing is properly seated on the drum. Inspect the top portion of the drum that it was not damaged, and the bearing rotates freely.

6. CAUTION: If there is evidence of clutch plate burning, replace the forward clutch cushion spring.

Install new forward clutch piston seals.
1. Install the forward clutch piston outer seal.
2. Install forward clutch cushion spring.
3. Install the forward clutch piston inner seal.

7. Note: Lubricate the forward clutch piston inner and outer seal with clean MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON V specification.

Install lip seal protector tools on the forward clutch piston.
1. Install the Outer Seal Protector to the forward clutch piston outer seal.
2. Install the Inner Seal Protector to the forward clutch piston inner seal.

8. CAUTION: Care must be taken to prevent damage to the seals.

As you install the forward clutch piston into the forward clutch cylinder, remove the Inner and Outer Seal Protectors.

9. Install the 15 forward clutch piston springs and the forward clutch piston spring retainer.
1. Install the 15 forward clutch piston springs.
2. Install the forward clutch piston spring retainer.

10. CAUTION: Do not fully depress the Clutch Spring Compressor or damage to the spring retainer may occur.

Use the Clutch Spring Compressor to install the forward clutch piston spring retaining ring.
1. Install the Clutch Spring Compressor and compress the forward clutch springs.
2. Install the forward clutch piston spring retaining ring.

11. CAUTION: The forward clutch friction plates are directional and must be installed with grooves pointing counterclockwise (I.D. to O.D.) and the word "TOP" facing up.

CAUTION: If new plates are used, they should be soaked in clean transmission fluid for at least 30 minutes before assembly.

When installing friction plates, the word "TOP" should face up. If reusing plates, grooves must be installed counterclockwise. Install the direct clutch disc pack.

12. Install the steel clutch plates and friction clutch plates (quantity model dependent) in alternating order starting with a steel clutch plate.

13. CAUTION: The retaining ring is a select fit.

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

14. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Make sure the drum is facing down as shown. Failure to follow these instructions may result in personal injury.

Air check the forward clutch piston.
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.

15. Check forward clutch disc pack free play.
1. Press down on 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.