Forward Clutch

FORWARD CLUTCH

COMPONENTS:

DISASSEMBLY
1. INSPECT PISTON STROKE OF FORWARD CLUTCH





2. REMOVE FORWARD CLUTCH FLANGE HOLE SNAP RING
(a) Using a screwdriver, remove the forward clutch flange hole snap ring from the input shaft sub-assembly.





3. REMOVE FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC
(a) Remove the clutch flange, 4 forward multiple disc clutch clutch discs and 4 plates from the input shaft sub-assembly.





4. REMOVE FORWARD CLUTCH PISTON RETURN SPRING SHAFT SNAP RING
(a) Place SST on the spring retainer and compress the springs with press.
SST 09350-32014 (09351-32070)
(b) Using snap ring pliers, remove the forward clutch piston return spring shaft snap ring from the input shaft sub-assembly.





5. REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY
(a) Remove the forward clutch return spring sub-assembly from the input shaft sub-assembly.





6. REMOVE FORWARD CLUTCH PISTON SUB-ASSEMBLY
(a) Apply compressed air into the oil passage to remove the forward clutch piston sub-assembly. If the forward clutch piston sub-assembly does not come out, use needle-nose pliers to remove it.





(b) Using a screwdriver, remove the 2 O-rings from the forward clutch piston sub-assembly.





7. REMOVE INPUT SHAFT OIL SEAL RING
(a) Remove the 3 input shaft oil seal rings from the input shaft sub-assembly.

8. INSPECT FORWARD CLUTCH PISTON SUB-ASSEMBLY
9. INSPECT FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC

INSPECTION





1. INSPECT PISTON STROKE OF FORWARD CLUTCH
(a) Using a dial indicator (long type pick or SST), measure the forward clutch piston stroke while applying and releasing compressed air (392 to 785 kPa, 4 to 8 kgf/cm2, 57 to 114 psi).
SST 09350-32014 (09351-32190)
Piston stroke: 1.41 to 1.81 mm (0.0555 to 0.0713 in.)

If the piston stroke is non-standard, select another flange.

HINT: There are 5 different thickness for the flange.

Flange thickness:

2. INSPECT FORWARD CLUTCH PISTON SUB-ASSEMBLY
(a) Check that the check ball is free by shaking the forward clutch piston sub-assembly.
(b) Check that the valve does not leak by applying low-pressure compressed air.





3. INSPECT FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC
(a) Check if the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them.

HINT:
^ If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace all discs.
^ Before assembling new discs, soak them in ATF for at least 15 minutes.

REASSEMBLY





1. INSTALL INPUT SHAFT OIL SEAL RING
(a) Install the 3 input shaft oil seal rings to the input shaft sub-assembly.

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

HINT: After installing the input shaft oil seal rings, check that they move smoothly.





2. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY
(a) Install 2 new O-rings to the forward clutch piston sub-assembly.





(b) Coat the O-rings with ATF and press the forward clutch piston sub-assembly into the input shaft sub-assembly with the cup side up, being careful not to damage the O-ring.





3. INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY
(a) Install the forward clutch return spring sub-assembly to the input shaft sub-assembly.





4. INSTALL FORWARD CLUTCH PISTON RETURN SPRING SHAFT SNAP RING
(a) Place SST on the forward clutch return spring sub-assembly, and compress the forward clutch return spring sub-assembly with press.
SST 09350-32014 (09351-32070)
(b) Using snap ring pliers, install the forward clutch piston return spring shaft snap ring to the input shaft sub-assembly.

HINT: Be sure the end gap of the snap ring is not aligned with the spring retainer claw.





5. INSTALL FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC
(a) Install the 4 plates and 4 forward multiple disc clutch clutch discs in order to the input shaft sub-assembly.
Install in order:
P = Plate D = Disc F = Flange
P - D - P - D - P - D - P - D - F
(b) Install the clutch flange with the flat side facing downward.





6. INSTALL FORWARD CLUTCH FLANGE HOLE SNAP RING
(a) Using a screwdriver, install the forward clutch flange hole snap ring to the input shaft sub-assembly.
(b) Check that the end gap of forward clutch flange hole snap ring is not aligned with one of the cutouts.

7. INSPECT PISTON STROKE OF FORWARD CLUTCH