Direct Clutch

Direct Clutch






DISASSEMBLY
1. Disassemble as shown in the illustration, referring to the following notes:





Retaining Ring (Reverse Clutch Hub)
^ Support the forward/coasting/direct clutch cylinder on a block so that the reverse clutch hub is facing up and the direct clutch hub/shell is not touching the workbench.





Retaining Ring (Reverse Clutch)
1. Use the Special Service Tools (SSTs) or equivalent to compress the return spring assembly on the reverse clutch.





2. Remove the reverse clutch retaining ring.





Retaining Ring (Direct Clutch)
1. Use the SST or equivalent to compress the return spring assembly on the direct clutch.





2. Remove the direct clutch retaining ring.





Direct Clutch Piston
^ Remove the direct clutch piston by using external snap ring pliers as shown in the illustration.





Retaining Ring (Forward And Coasting Clutch)
1. Use the SSTs or equivalent to compress the return spring assembly on the forward and coasting clutch.





2. Remove the forward and coasting clutch retaining ring.
3. Inspect all parts and repair or replace as necessary.

INSPECTION
- Springs must be the same length.
- Springs must not be twisted.
- Springs must not be damaged.

ASSEMBLY
- Assemble in the reverse order of disassembly, referring to the following steps.





1. Install a new inner forward clutch piston seal in the forward/coasting/direct clutch cylinder.





2. Install a new outer seal on the forward clutch piston.
3. Install the forward clutch piston in the forward/coasting/direct clutch cylinder.





4. Lubricate and install the coasting clutch piston in the SST.





5. Use the SST or equivalent to install the coasting clutch piston into the forward clutch piston.





6. Install the return spring assembly.





7. Use the SST or equivalent to compress the return spring assembly.





8. Install the retaining ring.
9. Remove the SST.





10. Install the forward and coasting clutch plates.





11. Install the forward clutch plate retaining ring (selective fit).





12. Use a feeler gauge to measure the clearance between the clutch plates and the forward clutch plate retaining ring. Make a second measurement on the opposite side. Average the two measurements to get the clearance.





13. The standard clearance is 0.50 - 1.09 mm (0.02 - 0.04 inch). If the clearance is not within the specification, select and install the proper thickness retaining plate to obtain the standard clearance.





14. Install the forward/coasting/direct clutch cylinder hub seal ring on the forward/coasting/direct clutch cylinder.





15. Install a new outer seal on the direct clutch piston.





16. Install a new inner piston seal in the forward/coasting/direct clutch cylinder.





17. Lubricate the seals and install the direct piston in the forward/coasting/direct clutch cylinder.





18. Install the return spring assembly.





19. Use the SSTs or equivalent to compress the return spring assembly.





20. Use a pair of snap ring pliers to install the retaining ring.
21. Remove the SST.





22. Install the direct clutch plates.





23. Install the direct clutch plate retaining ring (selective fit)





24. Measure the direct clutch clearance as follows:
^ Install a dial indicator on the side of the forward/coasting/ direct clutch cylinder and zero the needle on the pressure plate.
^ Use two picks to pull the pressure plate upward. Observe the dial indicator reading.
^ Make a second measurement on the opposite side. Average the two measurements to get the clearance.





25. The standard clearance is 0.52 - 1.12 mm (0.02 - 0.04 inch). If the clearance is not within the specification, select and install the proper thickness retaining ring to obtain the standard clearance.





26. Lubricate and install the reverse clutch piston in the SST or equivalent.





27. Use the SST or equivalent to install the reverse clutch piston with integral seals.





28. Install the return spring assembly.





29. Use the SSTs or equivalent to compress the return spring assembly.





30. Use a pair of snap ring pliers to install the retaining ring.
31. Remove the SSTs.





32. Install the reverse clutch plates.





33. Install the reverse clutch plate retaining ring (selective fit).





34. Use a feeler gauge to measure the clearance between the clutch plates and the reverse clutch plate retaining ring. Make a second measurement on the opposite side. Average the two measurements to get the clearance.





35. The standard clearance is 0.33 - 0.89 mm (0.01 - 0.04 inch). If the clearance is not within the specification, select and install the proper thickness retaining ring to obtain the standard clearance.

CAUTION: Tabs on direct clutch thrust washers must be seated in return spring assembly.





36. Install the direct clutch thrust washer on the forward/coasting/direct clutch cylinder with the tabs facing down.





NOTE: Ensure that the scarf cut seals are overlapped correctly.





37. Install the two reverse clutch seal rings.





38. Support the forward/coasting/direct clutch cylinder on a block so that the direct clutch faces upward.





39. Install the direct clutch hub/shell on the forward/coasting/direct clutch cylinder.





40. Install the reverse clutch drum.





41. Install the reverse clutch hub.





42. Install the reverse clutch hub retaining ring.





43. Flip the assembly over. Use the SST to size the forward/coasting/direct clutch cylinder hub seal. Leave the seal sizer on until the assembly in installed in the case.





44. Lubricate the pump seal rings (#1-#7) with ATF.
45. Install the thrust bearing on a pump support.
46. Lower the forward/coasting/direct clutch cylinder and reverse clutch drum assembly on the oil pump as shown in the figure.

WARNING: Wear eye protection when using compressed air.

47. Apply compressed air 275 kPa (40 psi) to each clutch passage and listen for a dull thud sound when the clutch applies.
48. If a hissing sound occurs during the check, disassemble and locate the source of the leakage.
49. Lift the cylinder and drum assembly from the oil pump.