Intermediate Clutch Cylinder

Disassembly

Special Tools:

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

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





2. CAUTION: Do not fully compress spring retainer.

Compress intermediate clutch return spring assembly using Clutch Spring Compressor T65L-77515-A. Remove retaining ring.





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

Remove intermediate clutch balance piston assembly from intermediate clutch cylinder.





4. Remove intermediate clutch return spring assembly.





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

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





6. Clean and inspect intermediate clutch cylinder. Replace intermediate clutch piston inner seal.

Assembly

1. NOTE: Lightly coat all seals and surfaces with petroleum jelly before piston installation.





Install intermediate clutch piston and seal assembly to intermediate clutch cylinder.





2. Install intermediate clutch return spring assembly to intermediate clutch cylinder.





3. Install Intermediate Clutch Balance Piston Seal Protector T94P-77001-L.H.

4. NOTE: Lightly coat all seals and surfaces with petroleum jelly before piston installation.





Install intermediate clutch balance piston and seal assembly to direct and intermediate clutch. cylinder using Intermediate Clutch Balance Piston Seal Protector T94P-77001-LH.

5. CAUTION: Do not fully compress spring retainer.





With piston seal protector in place, compress balance piston intermediate clutch support and spring using Clutch Spring Compressor T65L-77515-A. Install retaining ring.





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

Remove clutch spring compressor and piston seal protector.
Install wave spring, clutch pack assembly, clutch pressure plate and clutch pressure plate retaining snap ring.





7. Use Dial Indicator/Magnetic Base D78P-4201-B or equivalent to check clutch pack clearance. Push downward on clutch pack. Release pressure and zero the dial indicator. Lift pressure plate to bottom of retaining ring. Note dial indicator reading. Take two readings, 180 degrees apart, and determine the average of the two readings.

Selective Retaining Ring Thickness:

8. The clearance should be 1.28-1.76 mm (0.050-0.069 inch); if the clearance is not within specifications, selective retaining rings are available in the thicknesses shown.
9. After installing correct retaining ring, recheck clearance.