Forward Clutch

COMPONENTS

DISASSEMBLY OF FORWARD CLUTCH

1. CHECK PISTON STROKE OF FORWARD CLUTCH

Using a dial indicator (long type pick or SST), measure the forward clutch piston stroke applying and releasing the compressed air (4 - 8 kg/Sq. cm, 57 - 114 psi, 392 - 785 kPa) as shown.
SST 09350-32014 (09351-32190)

Piston stroke: 1.41 - 1.82 mm (0.0555 - 0.0717 in.)

If the piston stroke is greater than the maximum, inspect each component.

2. REMOVE SNAP RING FROM CLUTCH DRUM

3. REMOVE FLANGE, DISCS AND PLATES

4. REMOVE RETURN SPRING

a. Place SST on the spring retainer and compress the springs with a shop press.
SST 09350-32014 (09351-32070)

b. Remove the snap ring using snap ring pliers.

c. (A540E) Remove the return spring.

(A540H) Remove the spring retainer and eighteen return springs.

5. REMOVE CLUTCH PISTON

a. Apply compressed air into the oil passage to remove the piston.
If the piston does not come out use needle-nose pliers to remove it.

b. Remove the two O-rings from the piston.

6. IF NECESSARY, REMOVE OIL SEAL RINGS

(A540E) Remove the three oil seal rings from the shaft.

(A540H) Remove the two oil seal rings from the shaft.

INSPECTION OF FORWARD CLUTCH

1. INSPECT CLUTCH PISTON
a. Check that the check ball is free by shaking the piston.
b. Check that the valve does not leak by applying low- pressure compressed air.

2. INSPECT DISCS, PLATES AND FLANGE
Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them.

NOTE:
- If the lining of the disc is exfoliated or discolored, or even a part of the printed numbers are defaced, replace all discs.
- Before assembling new discs, soak them in ATF for at least fifteen minutes.

ASSEMBLY OF FORWARD CLUTCH

1. (A540E, A540H)
INSTALL OIL SEAL RINGS
Install the three oil seal rings (A540E) or two oil seal rings (A540H) to the shaft.

CAUTION: Do not spread the ring ends more than necessary.

NOTE: After installing the oil seal rings, check that they move smoothly.

2. INSTALL CLUTCH PISTON TO CLUTCH DRUM
a. Install the two new O-rings to the piston.

b. Coat the O-rings with ATF.
c. Press the piston into the drum with the cup side up, being careful not to damage the O-rings.

3. INSTALL PISTON RETURN SPRINGS
a. Place the return spring and snap ring onto the piston.
b. Place SST on the spring retainer, and compress the springs with a shop press.
SST 09350-32014 (09351-32070)

c. Install the snap ring with snap ring pliers. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

4. INSTALL PLATES, DISCS AND FLANGE
a. Install the plates and discs.
Install in order: P=Plate D=Disc
P-D-P-D-P-D-P-D
b. Install the flange with the flat end facing downward.

5. INSTALL SNAP RING
Check that the end gap of snap ring is not aligned with one of the cutouts.

6. RECHECK PISTON STROKE OF FORWARD CLUTCH