Intermediate Clutch
DISASSEMBLEIntermediate Clutch Assembly:
1. Remove snap ring, clutch pack assembly, and wave spring or spacer.
2. Remove return spring snap ring and return spring using clutch spring compressor T65L-77515-A or equivalent.
3. Remove piston assembly, then the piston inner and outer seals.
ASSEMBLE
1. Check for free movement of check ball in cylinder.
2. Install inner and outer piston seals with lip seal facing toward bottom of cylinder.
3. Install piston assembly using clutch seal lip protector T86P-70548-A or equivalent.
4. Install snap ring and return spring using T65L-77515-A or equivalent.
5. Install wave spring or spacer clutch pack and snap ring.
6. Check intermediate clutch pack clearance as follows:
Measuring Intermediate Clutch Pack Clearance:
a. Install suitable dial indicator as shown in the Measuring Intermediate Clutch Pack Clearance image.
b. Push downward on clutch pack with at least 10 lbs 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 0.044-0.111 inch on models without wave spring or spacer or 0.040-0.119 inch on models with wave spring or spacer. If clearance is not within specifications, replace select snap ring. Select snap rings are available in the following thicknesses: 1988-1989 models 0.049-0.053, 0.065-0.069, 0.081-0.085 0.098-0.102, and 0.114-0.118 inch and on 1990-1991 models, 0.047-0.051, 0.066-0.070, 0.084-0.088, 0.103-0.107, and 0.120-0.124 inch.
f. After installing correct snap ring, recheck clearance.