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 tool No. 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, as shown in the Direct Clutch Assembly image.
2. Install piston assembly using Clutch Seal Lip Protector tool No. 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 in piston.
5. Install snap ring using tool No. 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 tools.
8. Check direct clutch pack clearance as follows:
Measuring Direct Clutch Pack Clearance:
a. Install suitable dial indicator as shown in the Direct Clutch Pack Clearance Measurement 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° 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 inch.
f. After installing correct snap ring, recheck clearance.