Direct Clutch
DISASSEMBLE1. Remove direct-intermediate cylinder bushing, if required, using suitable tools.
Direct Clutch Assembly:
2. Remove snap ring, pressure plate and clutch pack.
3. Remove return spring snap ring and return spring using clutch spring compressor T65L-77515-A or equivalent.
4. Remove two piece piston assembly, then disassemble the two piece piston.
5. Remove piston inner and outer lip seals.
ASSEMBLE
1. Install inner and outer piston seals with lip seal facing toward bottom of cylinder.
2. Install piston assembly using clutch seal lip protector T86P-70548-A or equivalent.
3. Install piston outer ring and ensure check ball has free movement.
4. Install return spring in cylinder, aligning return spring notch with check ball.
5. Install snap ring using T65L-77515-A or equivalent.
6. Install clutch pack, pressure plate, and snap ring into cylinder.
7. If removed, install direct clutch bushing using suitable tool.
8. Check direct clutch pack clearance as follows:
Measuring Direct Clutch Pack Clearance:
a. Install suitable dial indicator as shown in the Measuring Direct Clutch Pack Clearance image.
b. Push downward on clutch pack with at least 10 lb of force, then release pressure and zero dial indicator.
c. Lift pressure plate to bottom of snap ring and note indicator reading.
d. Take two readings 180 degrees apart and determine average of both readings.
e. The clearance should be 0.031-0.0451 inch for three or four plates. If clearance is not within specifications, replace select snap ring. Select snap rings are available in the following thicknesses: 0.049-0.053, 0.065-0.069, 0.084-0.088, 0.102-0.106, and 0.119-0.123.