Assembly

CAUTION: Composition clutch plates and synthetic seals should not be cleaned in a vapor degreaser or with any type of detergent cleaner. To clean these parts, wipe them off with a lint free cloth. New clutch plates or bands should be soaked in the specified automatic transaxle fluid for two hours before being assembled.

NOTE:
- Clean the components with a suitable solvent and use compressed air to dry all parts and clean fluid passages. Inspect all clutches for damage and wear. Check each clutch piston and drum seal area for bun s or damage. Check for worn or broken springs.
- Clutch clearances are adjusted by the selection of snap ring thickness. If the clearance is not within specifications, adjust as necessary.








1. Inspect the reverse clutch piston.
- Verify that there is air flow when applying compressed air through the fluid hole on the return spring side. Apply a maximum air pressure of 392 kPa (57 psi).
- Verify that there is no air leakage when applying compressed air through the fluid hole opposite the return spring. Apply a maximum air pressure of 392 kPa (57 psi).
2. Apply the specified amount of automatic ban' fluid to the inner and outer faces of the new reverse clutch piston outer seal and the reverse clutch piston inner seal. Install the inner and outer seal on the reverse clutch piston.
- Reverse clutch piston outer seal inner diameter is 140.7 mm (5.539 inch).
- Reverse clutch piston inner seal inner diameter is 166.0 mm (6.535 inch).





3. Attach the Low Reverse Holding Piston Seal Protector T9OP-77000-EH to the reverse clutch piston to install the reverse clutch piston into the reverse clutch drum.
(1) Install the reverse clutch piston and the Low Reverse Holding Piston Seal Protector T9OP-77000-EH into the reverse clutch drum.
(2) Seat the reverse clutch piston by pushing evenly around the circumference of the piston. If necessary, use a screwdriver to seat the reverse clutch piston. Remove the seal protector.





4. Install the reverse clutch pressure spring. The reverse clutch pressure spring tabs face away from the reverse clutch piston.





5. Install the clutch pressure plate. The reverse clutch spacer step faces upward.








6. Install the reverse clutch pressure spring snap ring.
(1) Install the-reverse clutch pressure spring snap ring halfway down the reverse clutch drum.
(2) Use Return Spring Compressor T9OP-77000-CH to compress the reverse clutch spring and the reverse clutch spring spacer.
(3) Install the reverse clutch spring snap ring with a screwdriver.





7. Install the reverse clutch dished plate.





8. Install the reverse clutch disc pack.
- The installation order is steel-friction-steel-friction.





9. Install the reverse clutch pressure plate.





10. Install the reverse clutch pressure plate snap ring.





11. With the reverse clutch assembled, check the reverse clutch disc pack clearance.
(1) Use a feeler gauge to measure between the reverse clutch pressure plate and the reverse clutch pressure plate snap ring. The clearance should be 1.0-1.3 mm (0.040-0.051 inch). If the clearance is not within the specification, adjust it by selecting the proper snap ring. Refer to the Snap Ring Sizes chart below.
Snap Ring Sizes
2.0 mm (0.079 inch)
2.2 mm (0.087 inch)
2.4 mm (0.094 inch)
2.6 mm (0.102 inch)
2.8 mm (0.110 inch)
3.0 mm (0.118 inch)





12. Inspect the forward clutch piston.
- Verify that there is air flow when applying compressed air through the fluid hole on the return spring side. Apply a maximum air pressure of 392 kPa (57 psi).
- Verify that there is no air leakage when applying compressed air through the fluid hole opposite the return spring. Apply a maximum air pressure of 392 kPa (57 psi).
13. Apply the specified amount of automatic transaxle fluid to the inner and outer faces of the new forward clutch drum outer seal and the forward clutch drum inner seal. Install the inner and outer seal on the coasting clutch drum.
- Forward clutch piston inner seal inner diameter is 56.1 mm (2.209 inch).
- Forward clutch piston large seal inner diameter is 117.02mm (4.607 inch).





14. Install the coasting clutch drum into the reverse clutch drum. Align the coasting clutch drum with the F/C/R clutch drum as shown.
15. Apply the specified amount of automatic transaxle fluid to the inner and outer faces of the new coasting clutch piston outer seal and the coasting clutch piston inner seal. Install the inner and outer seal on the coasting clutch piston.
- The coasting clutch piston inner seal inner diameter is 104.2 mm (4.095 inch).





16. Install the coasting clutch piston into the coasting clutch drum.
(1) Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the-coasting clutch drum.
(2) Seat the coasting clutch piston by pushing evenly around the circumference of the piston, being careful not to damage the outer seal.





17. Install the coasting clutch return spring and retainer.





18. Install the coasting clutch return springs and retainer snap ring.
(1) Install Clutch Spring Compressor T65L-77515-A and compress the coasting clutch springs and retainer enough to install the coasting clutch return springs and retainer snap ring.
(2) Install the coasting clutch return springs and retainer snap ring.





19. Install the coasting clutch dished plate.





20. Install the coasting clutch disc pack.
- The installation order is steel-friction-steel-friction.





21. Install the coasting clutch pressure plate.





22. Install the coasting clutch pressure plate snap ring.





23. With the coasting clutch assembled, check the coasting clutch disc pack clearance.

NOTE: Take several measurements and calculate. the average value.

Use a feeler gauge to measure between the coasting clutch pressure plate and the coasting clutch pressure plate snap ring. The clearance should be 1.0-1.23 mm (0.0390-0.048 inch). If the clearance is not within the specification, adjust it by selecting the proper snap ring. Refer to the Snap Ring Sizes chart below.
Snap Ring Sizes
1.60 mm (0.063 inch)
1.75 mm (0.069 inch)
1.90 mm (0.075 inch)
2.05 mm (0.081 inch)
2.20 mm (0.087 inch)
2.35 mm (0.093 inch)
2.50 mm (0.098 inch)
2.65 mm (0.104 inch)





24. Install the forward clutch dished plate.





25. Install the forward clutch disc pack.
- The installation order is-steel-friction-steel-friction-steel-friction.





26. Install the forward clutch pressure plate





27. Install the forward clutch pressure plate snap ring.





28. With the forward clutch assembled, check the forward clutch disc pack clearance.

NOTE: Take several measurements and calculate the average value.

Use a feeler gauge to measure between the forward clutch pressure plate and the forward clutch pressure plate snap ring. The clearance should be 0.97-1.2mrn (0.039-0.048 inch). If the clearance is not within the specification, adjust it by selecting the proper snap ring. Refer to the Snap Ring Sizes chart below.
Snap Ring Sizes
1.80 mm (0.071 inch)
1.95 mm (0.077 inch)
2.10 mm (0.083 inch)
2.25 mm (0.089 inch)
2.40 mm (0.094 inch)
2.55 mm (0.100 inch)
2.70 mm (0.106 inch)
2.85 mm (0.112 inch)





29. Check each clutch operation after assembly.

NOTE: To check the clutch operation, apply a maximum air pressure of 392 kPa (57 psi).

(1) Position the clutch assembly onto the pump.
(2) Check the coasting clutch operation by applying compressed air to the coasting clutch hole at the pump. The clutch should make a solid apply sound, with no whistle or signs of leakage.
(3) Check the reverse clutch operation by applying compressed air to the coasting clutch hole at the pump. The clutch should make a solid apply sound, with no whistle or signs of leakage.
(4) Check the forward clutch operation by applying compressed air to the coasting clutch hole at the pump. The clutch should make a solid apply sound, with no whistle or signs of leakage.