AX4S

Direct Clutch Cylinder:

NOTE: The steel plates and friction discs which comprise the direct/intermediate clutch packs are manufactured with a dark coating. This dark coating is normal and does not necessarily indicate direct/intermediate clutch wear or failure. Carefully inspect the direct/intermediate clutch steel plates and friction discs prior to replacement.

DISASSEMBLY
1. Remove O-ring seals if not already removed.





2. Remove snap ring, clutch pressure plate and clutch pack.

NOTE: Number of components in clutch pack will vary with application.

Snap Ring Removal:

3. Remove snap ring and direct clutch support and spring using Clutch Spring Compressor T65L-77515-A.

CAUTION: Do not allow tool to bottom out on piston assembly.





4. Remove two-piece clutch piston.





5. Disassemble two-piece clutch piston.





6. Remove piston inner seal.





7. Remove piston outer lip seal.

ASSEMBLY
1. Verify free movement of check ball.





2. Install inner and outer piston lip seals (lip seals facing toward bottom of cylinder) and install into hub using Direct Clutch Lip Seal Protector T86P-70234-A. Be sure clutch piston is seated fully.





3. Install direct clutch piston ring.





4. Install direct clutch support and spring in cylinder aligning return spring notch with check ball in piston.

Snap Ring Removal:

5. Install snap ring using Clutch Spring Compressor T65L-77515-A.

CAUTION: Do not allow tool to bottom out on piston assembly.





6. Install clutch pack, clutch pressure plate and clutch pressure plate retaining snap ring into cylinder.
7. Check clutch pack clearance using feeler gauge or Dial Indicator with Bracketry TOOL-4201-C or equivalent. Push firmly downward on the clutch pack. Release pressure and zero dial indicator. Lift pressure plate to the bottom of the clutch pressure plate retainer snap ring. Note dial indicator reading. Take two readings, 180° apart, and determine the average of the two readings. The clearance should be: 1.04-1.55 mm (0.041-0.061 inch). If the clearance is not within specification, selective snap rings are available in the following thickness:

Thickness: Part Number
1.24-1.34mm (0.049-0.053 inch): E6SP-7G367-AA
1.66-1.76mm (0.065-0.069 inch): E6SP-7G347-AA
2.08-2.18mm (0.082-0.086 inch): E6SP-7G347-BA
2.50-2.60mm (0.098-0.102 inch): E6SP-7G347-CA
2.92-3.02mm (0.115-0.119 inch): E6SP-7G347-DA





8. After installing the correct snap ring, check the clearance.