Transfer Clutch

A: DISASSEMBLY





1. Remove the seal ring.

CAUTION: Be careful not to damage the seal ring.





2. Using a press and Special Service Tool(SST), remove the ball bearing.
(SST) 498077000 REMOVER

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 SST1, SST2 and SST3, and take out the spring retainer.
SST1 399893600 PLIERS
SST2 398673600 COMPRESSOR
SST3 498627000 SEAT





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

B: 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.

C: ASSEMBLY





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





2. Install piston.
1. Connect piston to rear drive shaft (until it reaches hole in valve body).
2. Install spring retainer to piston.
3. Using SST1, SST2 and SST3, attach transfer piston seal to SST2.
SST1 499247400 INSTALLER
SST2 499257400 PISTON GUIDE
SST3 498267400 TABLE

CAUTION: Be careful not to tilt transfer piston seal.





4. Place SST3 onto rear drive shaft so that spring can be inserted into hole in transfer piston seal.
5. Attach SST2 to rear drive shaft. Using SST1, press into place.
SST1 499247400 INSTALLER
SST2 499257300 SNAP RING OUTER GUIDE
SST3 499257400 PISTON GUIDE

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 SST1, SST2 and a press.
SST1 398673600 COMPRESSOR
SST2 498627000 SEAT





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 SST.
SST 899580100 INSTALLER





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.

SST 899580100 INSTALLER