Intermediate Clutch

DISASSEMBLE

Exploded View Of Intermediate Clutch Assembly:

NOTE: Refer to the Exploded View of Intermediate Clutch Assembly when performing this procedure.

1. Using expanding-type snap ring pliers, remove intermediate shaft retaining ring.
2. Remove intermediate shaft from intermediate clutch cylinder and inspect shaft stop ring. Remove stop ring if damaged.
3. Remove clutch pack retaining ring, pressure plate, clutch pack, and wave spring.
4. Remove seal rings from clutch cylinder hub.

Removing And Installing Clutch Spring:

5. Using a bench vise, clutch spring compressor tool No. T81P-70222-A, and clutch spring compressor extension tool No. T80L-77515-A or equivalent, remove piston retaining ring.
6. Remove retaining ring and piston return spring retainer.
7. Remove clutch piston using pliers.
8. Remove piston seal from intermediate clutch cylinder.
9. Remove seal from clutch piston.

ASSEMBLE
1. Inspect piston check ball. Ensure ball is present and free in cage.
2. Install seal on piston.
3. Install piston seal in clutch cylinder.
4. Apply light film of petroleum jelly to piston seals, clutch cylinder seal area, and clutch piston inner seal area, then install clutch piston.
5. Position piston return spring retainer and piston retaining ring.
6. Install piston retaining ring using a bench vise, clutch spring compressor tool No. T81P-70222-A and clutch spring compressor extension tool No. T80L-77515-A or equivalent, as shown in the Removing And Installing Clutch Spring image.
7. Install seal rings on clutch cylinder hub.
8. Install wave spring, clutch pack, and pressure plate.
9. Install clutch pack retaining ring.
10. Check clearance between clutch retaining ring and pressure plate is as follows:

Checking Clutch Pack Clearance:

a. Push downward on clutch pack with at least ten pounds of pressure. Release pressure, then zero dial indicator tool No. TOOL-4201-C or equivalent.
b. Lift pressure plate to bottom of retaining ring. Note dial indicator reading then take another reading 180° apart and use average.
c. The clearance should be 0.030-0.055 inches for the reverse clutch and 0.030-0.044 inches for the three intermediate clutch plates.
d. If clearance is not satisfactory, selective snap rings are available for the intermediate clutch in the following thicknesses; 0.049-0.053 inch, 0.059-0.063 inch, and 0.070-0.074 inch. Reverse clutch snap rings are available in the following thicknesses; 0.049-0.053 inch, 0.066-0.070 inch, 0.083-0.087 inch, and 0.099-0.103 inch.
11. Install correct snap ring and recheck clearance.
12. If removed, install stop ring on intermediate shaft, then install intermediate shaft into clutch cylinder.
13. Install intermediate shaft retaining ring.