Direct Clutch

DISASSEMBLE

Exploded View Of Direct Clutch Assembly:

NOTE: Refer to the Exploded View Of Direct Clutch Assembly image when performing this procedure.

1. Remove sun gear/clutch race assembly and No. 8 thrust washer.
2. Remove one-way clutch and clutch pack retaining ring.
3. Remove pressure plate, clutch pack, and wave spring.
4. Remove No. 9 thrust bearing.

Removing And Installing Piston Retaining Ring:

5. Remove piston retaining ring using a bench vise, clutch spring compressor tool No. T81P-70235-A, and clutch spring compressor extension tool No. T80L-77515-A or equivalent.
6. Remove retaining ring and piston return spring retainer, then using pliers, remove the clutch piston.
7. Remove piston seal from clutch cylinder.
8. Remove seal from clutch piston.

ASSEMBLE
1. Inspect clutch cylinder check ball. Ensure ball is present and free in cage.
2. Install seal on clutch cylinder.
3. Install seal on clutch piston. Ensure piston seal lip faces up.
4. Apply light film of petroleum jelly to piston seals, clutch seal area, and clutch piston inner seal area, then install clutch piston.
5. Position piston return spring retainer and piston retaining ring, then compress and install piston retaining ring, as shown in the Removing And Installing Piston Retaining Ring image.
6. Install No. 9 thrust bearing.
7. Install wave spring, clutch pack, pressure plate, and clutch pack retaining ring.
8. Install one-way clutch, then the No. 8 thrust washer.
9. Ensure clearance between clutch retaining ring and pressure plate as follows:

Checking Clearance Between Clutch Retaining Ring And Pressure Plate:

a. Push downward on clutch pack with at least ten pounds of pressure. Release pressure and 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 0.040-0.056 inch for three plates. If clearance is off, selective snap rings are available in the following thicknesses 0.050-0.054 inch, 0.062-0.066 inch, and 0.075-0.079 inch.
10. Install correct snap ring and recheck clearance.
11. Install sun gear/clutch race assembly.

NOTE: One-way clutch allows sun gear/clutch race to rotate in one direction only.