Transfer Clutch Overhaul

DISASSEMBLY
1. Remove the seal ring.

CAUTION: Be careful not to damage the seal ring.





2. Using a press and Special Tool (ST), remove the ball bearing.
ST 498077000 REMOVER or equivalent.

CAUTION: Do not reuse the bearing.





3. Remove the snap ring, and take out the pressure plate, drive plates, and driven plates.





4. Remove the snap ring with ST1, ST2 and ST3, and take out the spring retainer.
ST1 399893600 Pliers or equivalent.
ST2 398673600 Compressor or equivalent.
ST3 498627000 Seat or equivalent.





5. Apply compressed air to the rear drive shaft to remove the piston.

INSPECTION
1. Check the drive plate facing for wear and damage.
2. Check the snap ring for wear, return spring for permanent set and breakage, and spring retainer for deformation.
3. Check the lathe cut ring for damage.





ASSEMBLY
1. Install the lathe cut seal ring to the I.D./O.D. of the transfer clutch piston.





2. Install piston.
a. Connect piston to rear drive shaft (until it reaches hole in valve body).
b. Install spring retainer to piston.
c. Using ST1, ST2 and ST3, attach transfer piston seal to ST2.
ST1 499247400 Installer or equivalent.
ST2 499257400 Piston Guide or equivalent.
ST3 498267400 Table or equivalent.

CAUTION: Be careful not to tilt transfer piston seal.





d. Place ST3 onto rear drive shaft so that spring can be inserted into hole in transfer piston seal. (5) Attach ST2 to rear drive shaft. Using ST1, press into place.
ST1 499247400 Installer or equivalent.
ST2 499257300 Snap Ring Outer Guide or equivalent.
ST3 499257400 Piston Guide or equivalent.

CAUTION: Do not allow lip of transfer piston seal to fold back.





3. Install the driven plates, drive plates, and pressure plate, and secure with a snap ring with ST1, ST2 and a press.
ST1 398673600 Compressor or equivalent.
ST2 498627000 Seat or equivalent.





4. Apply compressed air to see if the assembled parts move smoothly.





5. Check the clearance.
Standard Value: 0.2 - 0.6 mm (0.008 - 0.024 inch).
Allowable Limit: 1.6 mm (0.063 inch).
If the clearance is not within the specified range, select a proper pressure plate.





NOTE: Before measuring clearance, place the same thickness of shim on both sides to prevent pressure plate from tilting.





6. Press-fit the ball bearing with ST.
ST 899580100Installer or equivalent.
7. Coat the seal ring with Vaseline, and install it in the seal ring groove of the shaft.

CAUTION: Do not expand the seal ring excessively when installing.

ST 899580100 Installer or equivalent.