Assembly

Direct Clutch Cylinder:

ASSEMBLE






1. Replace inner piston seal using O-Ring Tool T71P-19703-C.

NOTE: Lip on seal faces bottom of clutch cylinder.





2. Make sure that check ball is in place on clutch piston. Lightly coat all seals and surfaces with petroleum jelly before piston installation. Use the Direct Clutch Lip Seal Protector T86P-70234-A. Install clutch piston and seal assembly into direct and intermediate clutch cylinder. Be sure that clutch piston is fully seated.
3. Install piston apply ring on piston. Make sure piston apply ring is fully seated.





4. Install direct clutch return spring assembly, aligning spring notch with check ball.





5. Use Clutch Spring Compressor T65L-77515-A to compress direct clutch return spring assembly. Use snap ring pliers to install retaining ring.

CAUTION: Do not allow tool to bottom out on piston to prevent component damage.





6. Remove tool. Install clutch pack, direct clutch pressure plate and clutch pressure plate retaining ring.

NOTE: Number of clutch plates may vary with application.





7. Install clutch pressure plate retaining ring. Check clutch pack clearance using Dial Indicator with Magnetic Base D78P-4201-B or equivalent. Push firmly downward on the clutch pack. Release pressure and zero the dial indicator. Lift pressure plate to the bottom of the snap ring. Note dial indicator reading. Take two readings, 180° apart, and determine the average of the two readings. The clearance should be 1.28-1.76 mm (0.050-0.069 inch).

8. If clearance is not within specifications, selective retaining rings are available in the following thicknesses:

Selective Retaining Ring: 4 Plate
1.24-1.34 mm (0.049-0.053 inch)
1.60-1.70 mm (0.062-0.067 inch)
1.95-2.05 mm (0.077-0.081 inch)
2.30-2.40 mm (0.091-0.094 inch)
2.65-2.75 mm (0.104-0.108 inch)

Selective Retaining Ring: 5 Plate
1.20-1.30 mm (0.047-0.051 inch)
1.59-1.69 mm (0.062-0.066 inch)
1.98-2.08 mm (0.078-0.082 inch)
2.37-2.47 mm (0.093-0.097 inch)
2.76-2.86 mm (0.109-0.113 inch)
3.15-3.25 mm (1.124-0.128 inch)

9. After installing correct retaining ring, recheck clearance.