Forward Clutch Cylinder

Disassembly

NOTE: Forward clutch hub may remain in shell during disassembly.

1. Remove forward clutch hub and No. 3 forward clutch hub front bearing (7F231), if not already removed.
   
   
   
   

2. Remove clutch pack clutch pressure plate retainer snap ring (7D483).

   NOTE: To aid handling, clutch may be set in the extension housing (7A039) or a 51mm (2 inch) diameter hole may be cut in the work bench.

   
   
   
   
   

3. Remove clutch pack, clutch pressure plate (7B066) and forward clutch pressure spring.
   
   
   
   

4. Compress piston return spring using Direct Clutch Spring Compressor T81P-70235-A.

   Place into a shop arbor press and apply only enough pressure to release spring tension on the snap ring.

   Remove snap ring and slowly release the press to remove spring compressor.
   
   
   
   

   NOTE: Air pressure may be required to remove clutch piston (7A262).

5. Remove clutch piston spring retainer (7A527), return spring and clutch piston.

6. Remove piston direct clutch inner seal (7C099) and outer piston seals.
   
   
   
   

7. Remove seals from forward clutch cylinder and shaft (7F207).

   NOTE: Make sure input shaft teflon seals are not damaged.

   NOTE: Solid shaft seals may be replaced with scarf-cut seals for service.

   
   
   
   
   

8. Make sure check balls in clutch cylinder are free and clean. Check for proper seating.
   
   
   
   

Assembly

1. Install new seals on clutch piston. Note direction of the sealing lip before installation.
   
   
   
   

   NOTE: Coat piston seals and clutch drum sealing area with petroleum jelly.

2. Install clutch piston as follows:
   1. Install Forward Clutch Lip Seal Protector (Inner) T80L-77140-A over clutch cylinder hub.
   2. Install clutch piston in Forward Clutch Lip Seal Protector (Outer), T68P-7D158-A.
      
      
      
      

3. Position seal protector and clutch piston in forward clutch cylinder and shaft. Push clutch piston to the bottom of the forward clutch cylinder and shaft using even thumb pressure. Remove seal protectors.
   
   
   
   

4. Install piston return spring and clutch piston spring retainer.
   
   
   
   

5. Compress piston return spring using Clutch Spring Compressor T65L-77515-A. Compress clutch piston only enough to allow clearance to install snap ring.
   
   
   
   

6. Install clutch pack in the following order:
   1. Forward clutch pressure spring.
   2. Clutch pack.
   3. Clutch pressure plate.
      
      
      
      

7. Install clutch pack clutch pressure plate retainer snap ring and check the clearance between the clutch pressure plate retainer snap ring and clutch pressure plate using Dial Indicator with Bracketry TOOL-4201-C or equivalent.

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

   If the clearance is not within specification, install the correct size retaining ring and recheck the clearance. Selective retaining rings are available in the following thicknesses:
   
   

   Selective Retaining Rings
   1.52-1.62mm (0.060-0.064 inch)
   1.87-1.98mm (0.074-0.078 inch)
   2.23-2.69mm (0.086-0.092 inch)
   2.59-2.69mm (0.102-0.106 inch)

   
   

   NOTE: Scarf-cut seals must be installed with mating surfaces as shown.

8. Install two scarf-cut seals on the forward clutch cylinder and shaft if original seals are damaged or missing.
   
   
   
   
   
   
   
   

   The clearance should be:

   • 1.27-2.26mm (0.50-0.089 inch)

9. Install No. 3 forward clutch hub front bearing. Install forward clutch hub into forward clutch cylinder and shaft, ensure forward clutch hub is against No. 3 forward clutch hub front bearing.