Clutch Removal and Installation
CLUTCH REMOVAL1. Refer to Group 22C of the service manual and remove the transfer assembly and transmission.
2. Prior to transmission removal be certain the shift lever is placed into the "P" position, then turn the ignition off.
NOTE:
If the shift rails are not in the neutral position, the clutch assembly cannot be removed.
^ Correct positioning of the shift rails can be confirmed by removing the two detents (top illustration) and look for the depressions in the shift rails (bottom illustration).
^ If you cannot see the depressions of one or both detents, use a small punch and hammer to tap the depressions into position.
If it is necessary to remove the detents, reinstall new detents included with the new clutch assembly
3. Remove the clutch assembly outer cover.
Remove three screws and retaining tabs around the outer edge of the cover. These parts will not be reused. A new cover, tabs and screws are included with the new clutch assembly.
4. Use a pry bar or large screw driver to remove the clutch cover.
5. Insert four pins of special tool MB992332-01 - Clutch remover & installer into four holes of the clutch assembly.
6. While pressing lightly on the tool rotate the tool back and forth to engage all four clutch disks.
The tool pins will bottom at the first shoulder when fully inserted.
7. Rotate the clutch assembly counterclockwise six or seven times to loosen the clutch assembly.
NOTE:
There will be slight break away resistance when rotating the clutch assembly (tightening torque is only 66 in lbs.). Do not use excessive torque to loosen the assembly. The transmission may not have shifted to neutral when you selected "P" range prior to turning the engine oft. Applying excessive torque can break the tool pins.
8. Insert expanding snap ring pliers to the openings shown. DO NOT HOOK THE CLUTCH DISCS. Lift the clutch assembly to remove it.
NOTE:
The upper needle bearing of the main shaft support may remain in the clutch assembly. Remove it and reinstall it to the the main shaft support.
CLUTCH INSTALLATION
Position the transmission so the bell housing mating surface is level before beginning clutch assembly installation.
CAUTION
The needle bearings and seal rings on the main shaft support are not available separately. Take care they are not damaged when installing the clutch assembly.
1. Ensure the upper main shaft support needle bearing is installed.
2. Set the new clutch assembly in place in the bell housing.
3. Rotate the clutch assembly back and forth to ensure it engages the oil pump gear.
4. Remove the shipping alignment pins from the clutch assembly.
5. Insert four pins of special tool MB992332 - Clutch remover & installer, into four holes of the clutch assembly.
6. While pressing lightly on the tool, rotate the tool back and forth to engage all four clutch disks.
The pins of the tool will bottom at the first shoulder when fully inserted.
7. Rotate the clutch assembly clockwise six or seven times to secure it.
8. Torque the clutch assembly to 66 +/- 8 in. lbs.
9. Install a new clutch cover (provided with the clutch assembly).
Insert special tool seal protector (M992314-01) into the new clutch cover.
a. Assemble two pieces of the seal protector.
b. Insert the protector through the cover seal from the top surface as shown.
c. From the underside of the cover remove the small part of the protector.
d. Place the assembled cover/seal protector over the clutch assembly with the protector aligned to the main shaft support.
e. Press the cover down until the protector no longer engages the seal.
f. Remove the tool.
g. Use special tool cover installer (MB998323-01) with a dead blow mallet to seat the cover into place.
1. Place the special tool as shown.
2. Alternately strike the center and ends of the tool's crossbar rotate the tool 900 and repeat. Continue this process until the cover is fully seated
h. Secure the cover with three new tabs and bolts (provided with the clutch assembly).
Torque the bolts to 89 +/- 8 in. lbs.
10. Drain the transmission oil cooler
11. Reinstall the transmission and transaxle. Refer to Group 22C of the service manual for installation details.
12. Replace the external oil filter with a new part (see parts information section later in this TSB).
13. Reinstall two drain plugs and fill the transmission with 6.6 qts of DIAQUEEN SSTF-1.
IMPORTANT
ONLY FILL THE TRANSMISSION WITH 6.6 QTS OF DIAQUEEN SSTF-1 IF THE TRANSMISSION FILTER IS REPLACED AND THE COOLER IS DRAINED. REFER TO THE SERVICE MANUAL FOR REFILL CAPACITIES IF COMPLETING OTHER REPAIRS. PROGRAM NEW TRANSMISSION CONTROL MODULE (TCM)