Forward Clutch Cylinder

Special Tools:

Disassembly
1. Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Replace the clutch cylinder if badly scored or damaged.
2. Check the fluid passage in the clutch cylinder for obstructions. Clean out all the fluid passages. Inspect the clutch piston for scores and replace if necessary. Inspect check balls for freedom of movement and proper seating.
3. Check the clutch release spring for distortion and cracks. Replace the spring (including wave spring) if distorted or cracked.
4. Inspect the composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Replace all parts that are deeply scored or burred.
5. Check the clutch plates for flatness and fit on clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat.
6. Check the clutch hub thrust surfaces for scores and clutch hub splines for wear.





7. Note: The forward clutch hub may remain in the shell during disassembly.

Remove the (A) forward clutch hub and the (B) No. 3 forward clutch hub front bearing.





8. Note: To aid handling, the forward clutch assembly may be set in the extension housing or a hole in the work bench.

Remove the clutch pack selective retaining ring.





9. Remove the (A) pressure plate, (B) clutch pack and (C) pressure spring.





10. CAUTION: Apply only enough pressure to release pressure on the retaining ring. If too much pressure is applied, the spring may break.

Use (A) Direct Clutch Spring Compressor and an arbor press to remove the (B) forward clutch retaining ring.
11. Slowly release the press and remove the forward clutch from the press.





12. Remove the (A) forward clutch retainer and the (B) return spring.





13. Note: Air pressure may be required to remove the forward clutch piston.

Remove the forward clutch piston.





14. Remove the (A) inner and (B) outer forward clutch piston seals.





15. Note: The seals are solid seals but will be replaced with scarf cut seals.

Remove the forward clutch input shaft seals.





16. Make sure the check ball in the clutch cylinder is free and clean. Check for proper seating.

Assembly
1. Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Replace the clutch cylinder if badly scored or damaged.
2. Check the fluid passage in the clutch cylinder for obstructions. Clean out all fluid passages. Inspect the clutch piston for scores and replace if necessary. Inspect check balls for freedom of movement and proper seating.
3. Check the clutch release spring for distortion and cracks. Replace the spring (including the wave spring) if distorted or cracked.
4. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Replace all parts that are deeply scored or burred.
5. Check the clutch plates for flatness and fit on the clutch hub serrations. Discard any plate that does not slide loosely on serrations or that is not flat.
6. Check the clutch hub thrust surfaces for scores and the clutch hub splines for wear.





7. Note: To aid handling, the forward clutch assembly may be set in the extension housing or a hole in the work bench.

Install the (A) inner and (B) outer forward clutch piston seals. Note the direction of the sealing rings before installation.





8. Note: Coat the piston seals and clutch drum sealing area with petroleum jelly.

Position the (A) forward Clutch Lip Seal Protector (Inner) on the clutch cylinder hub and (B) Forward Clutch Lip Seal Protector (Outer) on the clutch piston.





9. Install the forward clutch piston into the clutch drum.
- Push the piston to the bottom of the drum using even pressure.





10. Use (A) Direct Clutch Spring Compressor and an arbor press to compress the piston return spring and install the (B) retaining ring.
11. Slowly release the press pressure and remove the forward clutch.





12. Note: Before assembly, soak the new clutch discs in transmission fluid for 15 minutes.

Install the clutch pack assembly.
1. Install the pressure ring.
2. Install the clutch pack.
3. Install the pressure plate.





13. Install the clutch pack retaining ring.





14. Position and zero Dial Indicator With Bracketry on the forward clutch pack.
- Push downward on the clutch pack.
- Release pressure and zero the dial indicator.





15. Check the clutch pack clearance.
1. Lift up on the clutch pack until it fully seats against the clutch pressure plate retainer.
2. Read the dial indicator.
- If the clearance is not within specifications, install the correct size retaining ring.





Selective Retaining Ring





16. Note: Make sure the scarf-cut seals are mated correctly.

Slide the two scarf-cut seals on the input shaft. (A) is correct; (B) is incorrect mating.





17. Install the two scarf-cut seals on input shaft.





18. Install the (A) No. 3 forward clutch hub front bearing and the (B) forward clutch hub.