High Clutch and Reverse Clutch

A: DISASSEMBLY





1) Remove the snap ring, and take out the retaining plate, drive plates, driven plates.





2) Remove snap ring, and take out the retaining plate, drive plates and driven plates.





3) Using ST1 and ST2, remove snap ring.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT





4) Take out clutch cover, spring retainer, high clutch piston and reverse clutch piston.





5) Remove seal rings and lip seal from high clutch piston and reverse clutch piston.

B: INSPECTION
1) Drive plate facing for wear and damage.
2) Snap ring for wear, return spring for breakage or setting, and spring retainer for deformation.
3) Lip seal and lathe cut seal ring for damage.
4) Piston check ball for operation





C: ASSEMBLY
1) Install seal rings and lip seal to high clutch piston and reverse clutch piston.





2) Install high clutch piston to reverse clutch piston.





3) Install reverse clutch to high clutch drum.

NOTE: Align the groove on the reverse clutch piston with the groove on the high clutch drum during installation.





4) Install spring retainer to high clutch piston.





5) Install ST to high clutch piston.
ST 498437000 HIGH CLUTCH PISTON GAUGE
6) Install cover to high clutch piston.

CAUTION: Be careful not to fold over the high clutch piston seal during installation.





7) Using ST1 and ST2, install snap ring.

NOTE: After installing snap ring, remove STs.

ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 498437000 HIGH CLUTCH PISTON GAUGE





8) Install driven plate, drive plate and retaining plate to high clutch drum.

NOTE: Install thicker driven plate on the piston side.

9) Install snap ring to high clutch drum.





10) Apply compressed air intermittently to check for operation.





11) Measure the clearance between the retaining plate and snap ring.

CAUTION: Do not press down retaining plate during clearance measurements.

Standard value: 0.8 - 1.1 mm (0.031 - 0.043 inch)
Allowable limit: 1.5 mm (0.059 inch)





12) If specified tolerance limits are exceeded, select a suitable high clutch retaining plate.





13) Install driven plate, drive plate, retaining plate and snap ring.





14) Apply compressed air intermittently to check for operation.





15) Measure the clearance between the retaining plate and snap ring.

CAUTION: Do not press down retaining plate during clearance measurements.

Standard value: 0.5 - 0.8 mm (0.020 - 0.031 inch)
Allowable limit: 1.2 mm (0.047 inch)





16) If specified tolerance limits are exceeded, select a suitable high clutch retaining plate.