Direct Clutch Cylinder

Disassembly

NOTE: The friction discs which comprise the Direct/Intermediate Clutch Packs are manufactured with a special dark friction material. The dark color is normal and does not necessarily indicate clutch wear or failure. Carefully inspect the friction discs for wear or glazing prior to replacement.





1. Remove direct one-way clutch and No. 7 thrust washer.





2. Disassemble, clean and inspect direct one-way clutch and inner and outer races. Service as required.





3. CAUTION: Circular depressions on top of nylon cage must be visible when installed on inner race or transaxle may be improperly assembled.

NOTE: Outer race must rotate clockwise.

Assemble one-way clutch. Use petroleum jelly to hold parts together.





4. Remove two intermediate and direct clutch hub seals using O-Ring Tool T71P-19703-C. Discard O-ring seals.





5. CAUTION: Check for wear on intersplines of friction plates. If found worn, they must be replaced.

NOTE: Number of plates in clutch pack may vary with application.

Remove clutch pressure plate retaining ring, clutch pressure plate and clutch pack assembly.





6. CAUTION: Do not allow clutch spring compressor to bottom out on piston.

Compress direct clutch return spring assembly using Clutch Spring Compressor T65L-77515-A. Remove retaining ring with snap ring pliers.





7. Remove tool. Remove direct clutch return spring.





8. NOTE: Seal is part of piston and is serviced only as an assembly.

NOTE: Make sure check ball in piston moves freely.

Remove direct clutch piston and seal assembly from direct and intermediate clutch cylinder.





9. Separate piston and seal assembly from apply ring. Service as required.

Assembly





1. NOTE: Lip on seal faces bottom of clutch cylinder.

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





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

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





6. NOTE: Number of clutch plates may vary with application.

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





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 degrees apart, and determine the average of the two readings. The clearance should be 1.28-1.76 mm (0.050-0.069 inch).

Selective Retaining Ring Thickness:

8. If clearance is not within specifications, selective retaining rings are available in the following thicknesses:
9. After installing correct retaining ring, recheck clearance.