Direct Clutch Cylinder

Disassembly

1. After removing direct clutch hub, remove No. 7 direct clutch inner bearing (7F243) and direct clutch inner bearing washer (7F237).
   
   
   
   

2. Remove clutch pressure plate retainer snap ring (7D483). Remove and inspect clutch pack. Note the relation of clutch pressure plates (7B066) for assembly.
   
   
   
   

3. Using Clutch Spring Compressor T65L-77515-A compress the direct clutch support and spring (7F235). Remove piston retaining ring using expanding-type snap-ring pliers.
   
   
   
   

   NOTE: Use air pressure if necessary to remove clutch piston (7A262).

4. Remove direct clutch support and spring and clutch piston from direct clutch cylinder.
   
   
   
   

5. Remove direct clutch inner seal (7C099) from direct clutch and outer seal from clutch piston. Verify presence of check ball and that it moves freely.
   
   
   
   

Assembly

NOTE: Lubricate direct clutch inner seal and seal protector with petroleum jelly.

1. Install direct clutch inner seal on direct clutch as follows:
   1. Position Direct Clutch Lip Seal Protector T80L-77234-A over direct clutch cylinder.
   2. Position direct clutch inner seal over installer tool with the sealing lip facing down.
      
      
      
      

2. Install clutch piston outer seal. Note direction of sealing lip before installation. The lip should point toward bottom of clutch cylinder.
   
   
   
   

   NOTE: Coat direct clutch inner seal and outer piston seals, clutch cylinder sealing area and piston inner sealing area with petroleum jelly.

3. Install clutch piston as follows:
   1. Install clutch piston in Lip Seal Protector T80L-77254-A.
      
      
      
      
   2. Position tool in the direct clutch and push the clutch piston to the bottom of the direct clutch cylinder using even thumb pressure.
      
      
      
      

4. Install direct clutch support and spring and retaining ring using Spring Compressor T65L-77515-A.
   
   
   
   

5. Install clutch pack and clutch pressure plate.
   
   
   
   

   NOTE: TOOL-4201-C or equivalent may also be used for clearance check.

6. With clutch pressure plate retainer snap ring installed, check clearance between clutch pressure plate retainer snap ring and clutch pressure plate using a feeler gauge.

   Clutch pressure plate should be held downward as the clearance is checked.
   
   
   
   

7. The clearance should be:
   • Six Plate 1.57-2.16mm (0.062-0.085 inch).
     • If the clearance is not within limits, install the correct size retaining ring and check the clearance. Selective retaining rings are available in the following thicknesses:
   
   
   

   Selective Retaining Rings
   1.27-1.37mm (0.050-0.054 inch)
   1.62-1.72mm (0.064-0.068 inch)
   1.98-2.08mm (0.078-0.082 inch)
   2.33-2.43mm (0.092-0.096 inch)

   
   

8. Install No.7 direct clutch inner bearing washer and No. 7 direct clutch inner bearing (black side up toward direct clutch hub).
   
   
   
   

9. Install direct clutch hub.
   
   
   
   

10. Install two output shaft to direct clutch cylinder seals (7F274). Ensure output shaft to direct clutch cylinder seals are properly lapped.
    
    
    
    

11. Install output shaft hub (7D164). Install snap ring.
    
    
    
    

    NOTE: Make sure output shaft to case seals (7F273) are lapped properly.

12. Install three output shaft to case seals and output shaft O-ring seal.
    
    
    
    

13. Install No. 8 direct clutch bearing and race on direct clutch cylinder.
    
    
    
    

    NOTE: Direct clutch cylinder may be installed after ring gear (7A153) is installed to output shaft hub.

14. Install direct clutch cylinder on output shaft (7060).
    
    
    
    

15. Install ring gear and snap ring on output shaft.
    
    
    
    

16. Install following components as an assembly:
    • Intermediate one-way clutch
    • Reverse clutch
    • Forward clutch

17. Install reverse clutch assembly on forward clutch assembly.