Direct Clutch Cylinder

Special Tools:

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

Disassembly
1. Remove O-ring seals if not already removed.

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





Remove snap ring, clutch pressure plate and clutch pack.

3. CAUTION: Do not allow tool to bottom out on piston assembly.

Snap Ring Servicing:

Direct Clutch Support and Spring:

Remove snap ring and direct clutch support and spring using Clutch Spring Compressor 307-015 (T65L-77515-A).

Check Ball Alignment:

4. Remove two-piece clutch piston.

Clutch Piston:

5. Disassemble two-piece clutch piston.





6. Remove piston inner seal.





7. Remove piston outer lip seal.

Assembly
1. Verify free movement of check ball.

Special Tools:

2. Install inner and outer piston lip seals (lip seals facing toward bottom of cylinder) and install into hub using Direct Clutch Lip Seal Protector 307-168 (T86P-70234-A). Be sure clutch piston is seated fully.





3. Install direct clutch piston ring.

Direct Clutch Support and Spring:

4. Install direct clutch support and spring in cylinder aligning return spring notch with check ball in piston.

5. CAUTION: Do not allow tool to bottom out on piston assembly.

Snap Ring Servicing:

Install snap ring using Clutch Spring Compressor 307-015 (T65L-77515-A).





6. Install clutch pack, clutch pressure plate and clutch pressure plate retaining snap ring into cylinder.





7. Check clutch pack clearance using feeler gauge or Dial Indicator with Bracketry 100-002 (TOOL-4201-C) or equivalent. Push firmly downward on the clutch pack. Release pressure and zero dial indicator. Lift pressure plate to the bottom of the clutch pressure plate retainer snap ring. Note dial indicator reading. Take two readings, 180 degrees apart, and determine the average of the two readings. The clearance should be: 1.04-1.55 mm (0.041-0.061 inch). if the clearance is not within specification, selective snap rings are available in the following thicknesses:

Checking Clutch Pack Clearance:

After installing the correct snap ring, check the clearance.