Disassembly and Assembly

Intermediate 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 clutch pressure plate retainer snap ring, clutch pressure plate, clutch wave spring and clutch pack assembly.

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

Intermediate Clutch Support Snap Ring (3.0L):

2. Remove snap ring and intermediate clutch support and spring, using Clutch Spring Compressor T65L-77515-A.





3. Remove intermediate clutch piston.

Intermediate Clutch Piston Outer Seal (3.0L):

Intermediate Clutch Piston Inner Seal:

4. Remove clutch piston inner seal and clutch piston outer seal.

ASSEMBLY






1. Check for free movement of check ball in cylinder. Install clutch piston inner seal on cylinder hub and clutch piston outer seal (lips facing toward bottom of cylinder) on intermediate clutch piston and install intermediate clutch piston using Forward/Intermediate Clutch Outer Lip Seal Protector T86P-70548-A.

Intermediate Clutch Support Snap Ring (3.0L):

2. Install snap ring and intermediate clutch support and spring using Clutch Spring Compressor T65L-77515-A.





3. Install clutch pack, clutch pressure plate, clutch wave spring and clutch pressure plate retainer snap ring.

NOTE: Be sure step on clutch pressure plate faces up.

Measuring Intermediate Clutch Pack Clearance:

4. Check clutch pack clearance using Dial Indicator with Bracketry TOOL-4201-C or equivalent. Push firmly downward on the clutch pack. Release pressure and zero the 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: (4-plate) 1.14-1.70 mm (0.045-0.067 inch). If the clearance is not within specification, selective snap rings are available in the following thickness:
Thickness: Part Number
1.20-1.30 mm (0.047-0.051 inch): E7DP-7G346-AA
1.67-1.77 mm (0.066-0.070 inch): E7DP-7G346-BA
2.14-2.24 mm (0.084-0.088 inch): E7DP-7G346-CA
2.61-2.71 mm (0.103-0.107 inch): E7DP-7G346-DA
3.04-3.14 mm (0.120-0.124 inch): E7DP-7G346-EA