Direct Clutch Cylinder

Direct Clutch Cylinder





Special Tool(s)





Disassembly





1. Remove the direct one-way clutch assembly.
1. Remove the direct one-way clutch assembly.
2. Remove the direct clutch cylinder thrust washer.





2. Disassemble, clean and inspect the direct one-way clutch, inner and outer races.





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

NOTE: Outer race must rotate clockwise.

Assemble the one-way clutch.





4. Using the special tool remove the intermediate and direct clutch hub seal.





5. CAUTION: Check for wear on inner splices of friction plates. Replace if worn.

NOTE: The number of clutch packs may vary with application.

Remove the intermediate clutch pack.
1. Remove the snap ring.
2. Remove the clutch pressure plate.
3. Remove the clutch pack.





6. CAUTION: Do not allow the Clutch Spring Compressor to bottom out on the piston.

Using the special tool, compress the clutch spring and remove the snap ring.





7. Remove the direct clutch return spring.





8. NOTE: The seal is part of the piston and is serviced as an assembly. Make sure that the check ball in the piston moves freely.

Remove the piston and seal assembly.





9. Separate the piston and seal assembly from the apply ring.





10. Using the special tool remove the inner piston seal.

Assembly





1. NOTE: The lip on the seal must face toward the bottom of the clutch cylinder.

Install the inner piston seal.





2. NOTE: Make sure that the check ball is in place on the clutch piston. Lightly coat all the seals with petroleum jelly prior to installation.

Using the special tool, install the direct clutch piston and seal assembly making sure that it is fully seated.





3. Install the apply ring. Make sure that it is fully seated on the clutch piston.





4. NOTE: The notch on the direct clutch return spring must line up with the check ball on the direct clutch piston.

Install the direct clutch return spring.





5. CAUTION: Do not allow the Clutch Spring Compressor to bottom out on the piston.

Using the special tool and snap ring pliers, compress the clutch spring and install the snap ring.





6. CAUTION: Check for wear on the inner splices of the friction plates. Replace if worn.

NOTE: The number of clutch plates may vary with application.

NOTE: The clutch pressure plate must be installed with the chamfer edge facing up.

Install the intermediate clutch pack.
1. Install the intermediate clutch pack.
2. Install the clutch pressure plate.
3. Install the snap ring.





7. Using the special tool, measure the clearance between the retaining ring and the clutch cylinder lip.
8. If the clearance is not within specification, selective retaining rings are available. Check the clearance after installing the correct selective retaining ring.








Selective Retaining Ring