Forward Clutch
COMPONENTS
DISASSEMBLY
1. PLACE FORWARD CLUTCH INTO O/D SUPPORT
a. Place wooden blocks, etc, to prevent forward clutch shaft from touching the work stand, and place the O/D support on them.
b. Place the forward clutch into the O/D support.
2. CHECK PISTON STROKE OF FORWARD CLUTCH
Using SST and a dial indicator, measure forward clutch piston stroke while applying and releasing compressed air (186 kPa, 1.9 kgf/cm2, 27 psi). SST 09350-30020 (09350-06120)
Piston stroke: 0.60-0.90 mm (0.024-0.035 in.)
If the clearance is non-standard, inspect the discs.
3. REMOVE FLANGE, PLATE AND DISC
a. Using a screwdriver, remove the snap ring from the forward clutch drum.
b. Remove the flange, 5 plates and 5 discs.
c. Remove the cushion plate.
4. REMOVE PISTON RETURN SPRING
a. Place SST on the spring retainer and compress the return spring with a press. SST 09350-30020 (09350-07040)
b. Using SST, remove the snap ring. SST 09350-30020 (09350-07070)
c. Remove the piston return spring.
5. REMOVE FORWARD CLUTCH PISTON
a. Place the forward clutch drum onto the O/D support.
b. Hold the forward clutch piston with hand, apply compressed air (186 kPa, 1.9 kgflcm2, 27 psi) to the O/D support to remove the forward clutch piston.
c. Remove the forward clutch piston.
6. REMOVE 2 O-RINGS FROM PISTON
Using a small screwdriver, remove the 2 O-rings.
7. REMOVE 3 OIL SEAL RINGS FROM FORWARD CLUTCH
INSPECTION
1. INSPECT DISC, PLATE AND FLANGE
Check to see if the sliding surface 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: 20.08 mm (0.790 in.)
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 FORWARD CLUTCH PISTON
a. Coat 2 new O-rings with ATF and install them on the forward clutch piston.
b. Being careful not to damage the O-rings, press the clutch piston into the forward clutch drum with both hands.
3. INSTALL PISTON RETURN SPRING
a. Install the piston return spring.
b. Place SST on the spring retainer, and compress the return spring with a press. SST 09350-30020 (09350-07040)
c. Using SST, install the snap ring. SST 09350-30020 (09350-07070)
NOTICE: Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
4. INSTALL PLATE, DISC AND FLANGE
a. Install the cushion plate. CP = Cushion Plate
b. Install the flange, 5 plates and 5 discs.
c. Then install the flange, with the flat end facing downward. Install in order: P Plate, D = Disc P-D-P-D-P-D-P-D-P-D
d. Install the snap ring with a screwdriver.
NOTICE: Be sure the end gap of the snap ring is not aligned with the cutout portion of the forward clutch drum.
5. CHECK PISTON STROKE OF FORWARD CLUTCH
a. Using SST and a dial indicator, measure the forward clutch piston stroke while applying and releasing compressed air (186 kPa, 1.9 kgf/cm2, 27 psi). SST 09350-30020 (09350-06120)
Piston stroke: 0.60-0.90 mm (0.024-0.035 in.)
If the piston stroke is less than the limit, parts may have been assembled incorrectly, check and reassemble again. If the clearance is non-standard, select another flange.
HINT: There are 6 different flanges in thickness.