AX4N

Sun And Shell Assembly:

DISASSEMBLY





1. Install No. 7 thrust washer and direct one-way clutch assembly to intermediate clutch cylinder.

NOTE:
^ Make sure direct one-way clutch is fully seated.
^ No. 7 thrust washer tabs snap into direct clutch spring retainer





2. Install two new O-rings onto intermediate clutch cylinder.

NOTE: Lightly coat O-rings with petroleum jelly before installation.





3. Install forward clutch assembly into direct and intermediate clutch cylinder.

CAUTION: Do not damage O-rings on direct clutch hub.





4. Install No. 6 forward clutch thrust washer. Make sure washer tabs lock into oval holes on spring retainer assembly.

NOTE: Spring retainer assembly contains both oval and circular holes.





5. Install overdrive drum and one-way clutch assembly. Make sure that overdrive drum and one-way clutch are fully seated.

NOTE: Make sure overdrive drum and one-way clutch assembly are fully seated.





6. Install No. 10 forward sun gear thrust bearing to the intermediate clutch hub using petroleum jelly to hold the bearing in place.

NOTE: Lip on bearing goes over hub.





7. Turn assembly over. Install intermediate clutch hub with No. 10 thrust bearing to the intermediate clutch cylinder.





8. Install No. 11 forward sun gear thrust bearing to the intermediate clutch assembly using petroleum jelly to hold in place.

NOTE: Lip on bearing goes down over hub.





9. Install front sun gear and shell assembly over the direct/intermediate clutch assembly, and into the overdrive drum assembly.





10. Turn complete assembly (with overdrive drum) face-up. Install driven sprocket support into overdrive drum.

CAUTION: Be sure not to damage driven sprocket seals.

NOTE: Do not install No. 8 thrust washer or No. 9 bearing at this time.





11. Apply pressurized air to the driven sprocket support ports as shown to check for seals damaged during assembly. If air can be heard leaking past seals, the seals must be replaced.

WARNING: To prevent injury, wear eye protection when using pressurized air.

NOTE: Be sure shop air is dry and regulated at 276 kPa (40 psi).





12. Remove driven sprocket support from overdrive drum.