Forward Clutch

Forward Clutch









Forward Clutch Assembly









Disassembly

1. NOTE: The retaining ring is a select fit. See assembly procedure if installation of a new ring or clutch plate pack is required.

Remove the forward clutch pressure plate.

1. Remove the forward clutch retaining ring.

2. Remove the forward clutch pressure plate.





2. NOTE: 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: While removing or installing the retaining ring, slowly release tool pressure on clutch piston springs. Failure to follow this instruction may cause the assembly to separate forcefully, resulting in serious personal injury.

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

Using the Clutch Spring Compressor, remove the forward clutch piston 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 distortion.





6. WARNING: When using compressed air, never let air pressure exceed 138 kPa (20 psi) and always wear safety glasses. Compressed air may cause foreign material or parts to become airborne. Failure to follow this instruction may result in serious personal injury.

Remove the forward clutch piston.

1. Place the forward clutch cylinder with the 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 the forward clutch cushion spring.

3. Remove the forward clutch piston inner seal.





8. 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.

- 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.

9. Inspect the remaining forward clutch drum components for damage or wear, install new components as necessary.

1. Inspect the forward clutch cylinder surfaces for scores or burrs. Install a new forward clutch cylinder if it is badly scored or damaged.

2. Inspect the forward clutch piston for scores or burrs.

3. Make sure the check ball is free and clear of foreign material, has freedom of movement and is correctly seated.





10. Inspect the needle bearing for damage. If the bearing is damaged, install a new drum assembly.





Assembly

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

2. Install new forward clutch piston seals.

1. Install the forward clutch piston outer seal.

2. Install the forward clutch cushion spring.

3. Install the forward clutch piston inner seal.





3. NOTE: Lubricate the forward clutch piston inner and outer seal with clean transmission fluid.

Install Piston Seal Protectors on the forward clutch piston.

1. Install the Piston Seal Protector to the forward clutch piston outer seal.

2. Install the Piston Seal Protector to the forward clutch piston inner seal.





4. NOTICE: Care must be taken to prevent damage to the seals.

Install the forward clutch piston into the forward clutch cylinder, then remove the Piston Seal Protectors.

5. 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.





6. NOTICE: Do not fully depress the Clutch Spring Compressor or damage to the spring retainer can occur.

Using the Clutch Spring Compressor, install the forward clutch piston spring retaining ring.





7. NOTICE: The forward clutch friction plates are directional and must be installed with grooves pointing counterclockwise (ID to OD) and the word TOP facing up. Improper installation can result in transmission damage.

NOTE: If new plates are used, they should be soaked in clean transmission fluid 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.





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





9. NOTE: 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.





10. WARNING: When using compressed air, never let air pressure exceed 138 kPa (20 psi) and always wear safety glasses. Compressed air may cause foreign material or parts to become airborne. Failure to follow this instruction may result in serious 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.





11. 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.