Forward/Coast/Direct Clutches
DISASSEMBLEExploded View Of Forward/Coast/Direct Clutches:
1. Remove direct clutch pressure plate retaining ring and clutch plates.
2. Use clutch spring compressor tool No. T65L-77515-A or equivalent to compress direct clutch support and spring.
3. Remove direct clutch spring retaining ring using snap ring pliers, then release spring pressure carefully by removing tool.
4. Remove direct clutch return spring and piston assemblies, then separate outer lip seal from direct clutch piston assembly. Discard seal.
5. Remove direct clutch piston inner lip seal from forward/coast/direct clutch cylinder assembly, then discard seal.
6. Invert forward/coast/direct clutch cylinder and remove forward clutch pressure plate retaining ring, then the forward and coast clutch plates.
Forward/Coast Clutch Return Spring Compression:
7. Use clutch spring compressor tool No. T65L-77515-A or equivalent to compress forward/coast clutch return spring, then remove retaining ring with snap ring pliers.
8. Remove spring compressor tool and forward/coast clutch return spring, then use needle nose pliers to remove forward and coast clutch pistons.
9. Use 0-ring tool No. T71P-19703-C or equivalent to remove forward clutch piston inner lip seal from forward/coast/direct clutch cylinder, then separate
10. Separate coast clutch piston with integral seal from forward clutch piston.
ASSEMBLE
1. Soak internal spline clutch plates in clean transmission fluid for 15 minutes before assembly, then install forward clutch piston inner lip seal in forward/coast/direct clutch cylinder assembly.
Forward Clutch Piston Outer Lip Seal Installation:
2. Install forward clutch piston outer lip seal on piston, then position forward clutch piston assembly in forward/coast/direct clutch cylinder assembly.
Coast Clutch Piston Installation:
3. Place coast clutch piston in coast clutch piston seal protector tool No. T94P-77000D3 or equivalent, then use seal protector to install piston in forward clutch piston assembly.
4. Install forward/coast clutch return spring, then compress using clutch spring compressor tool No. T65L-77515-A or equivalent. Install retaining ring with snap ring pliers.
5. Remove spring compressor, then install forward and coast clutch plates and pressure plate retaining ring.
6. Use a feeler gauge to measure clearance between forward clutch pressure plate and retaining ring. If clearance is not 0.020-0.040 inch, choose a selective fit retaining ring to obtain standard clearance. Sizes available include 0.050-0.054 inch, 0.055-0.059 inch, 0.060-0.064 inch, and 0.065-0.069 inch.
Direct Clutch Piston Outer Lip Seal Installation:
7. Install direct clutch piston inner lip seal in forward/coast/direct clutch cylinder as shown in the Direct Clutch Piston Inner Lip Seal Installation image and outer lip seal on piston as shown in the Direct Clutch Piston Outer Lip Seal Installation image.
8. Install direct clutch return spring, then compress using spring compressor tool No. T65L-77515-A or equivalent. Install retaining ring with snap ring pliers.
9. Remove spring compressor, then install direct clutch plates and pressure plate retaining ring.
10. Measure direct clutch clearance as follows:
Dial Indicator Installation:
a. Install a dial indicator on side of forward/coast/direct clutch cylinder assembly and zero needle on direct clutch pressure plate.
Direct Clutch Clearance Measurement:
b. Use two picks to pull direct clutch pressure plate upward as shown in the Direct Clutch Clearance Measurement image. Observe dial indicator reading.
c. Measure again on opposite side, then average measurements to determine clearance.
11. If clearance is not 0.02-0.04 inch, choose a selective fit retainer snap ring to obtain standard clearance. Sizes available include 0.050-0.054 inch, 0.055-0.059 inch, 0.060-0.064 inch, and 0.065-0.069 inch.