Usage:
Start By:
a. disassemble case
1. Use a small hammer to tap adapter ring (1) and shims (2), if used, off the output end of the clutch stack.
2. Pry snap ring (3) out of the input end of the clutch stack with a screw driver.
3. Lift input shaft (4) off the clutch stack.
4. Examine three metal lock rings (5) on the input shaft. Each ring must turn freely on the input shaft. If any ring binds or appears damaged, all three rings must be removed and replaced with new parts.
5. Check bearing (6) on the input shaft. If the bearing does not rotate smoothly, or if it appears damaged, it must be pulled off the input shaft and replaced with a new part.
6. Remove pilot bearing (7) and thrust bearing (8) from output shaft (10).
7. Lift front clutch hub (9) out of the clutch stack.
8. Remove snap ring (11) securing front clutch assembly (12) to output shaft (10).
9. Lift front clutch assembly (12) off of the clutch stack.
10. Pry snap ring (14) out of the output end of the clutch stack with a screw driver.
11. Separate rear clutch assembly (13) from output shaft (10).
12. Remove snap ring (15) securing rear clutch hub (16) to output shaft (10).
13. Slide the rear clutch hub off of the output shaft.
14. Slide output gear (17), pilot bearing (18) and two thrust bearings (19) off the output shaft.
15. Check two seal rings (21) on the output shaft. If they appear damaged, remove and replace with new parts.
16. Examine four metal lock rings (20) on the output shaft. Each ring must turn freely on the output shaft. If any ring binds or appears damaged, all four rings must be removed and replaced with new parts.
17. Examine bronze-colored tube (22) and sleeve (23) near the end of the output shaft. These pieces must be finger-tight on the shaft. If either part turns at all, the output shaft must be replaced with a new part.
18. Check bearing (24) on the output shaft. If the bearing does not rotate smoothly, or if it appears damaged, it may be removed from the output shaft by removing snap ring (25). Replace the bearing with a new part, if necessary.
19. Disassemble clutch assemblies (12) and (13) as follows:
a. Lift six bronze clutch plates (26) and six steel separator plates (27) out of the clutch assembly.
Special Tool Dimensions
(a) 127 mm (5 in.). (b) 114 mm (4.5 in.). (c) 4.8 mm (.19 in.). (d) 74.7 mm (2.94 in.). (e) 79.5 mm (3.13 in.). (f) 12.7 mm (.50 in.)
NOTE: A special tool is needed to compress the spring in the clutch assembly in the following steps. Follow the specifications in the drawing above, to make this tool.
b. Set the special tool over the spring retainer inside the clutch assembly.
c. Use a hydraulic press on the special tool to compress the spring inside the clutch.
d. With the spring compressed, remove snap ring (28) from inside the clutch.
e. Slowly release the hydraulic pressure, and remove the special tool.
f. Remove spring retainer (29), spring (30), piston (31), and steel ball (32) from inside cylinder (33).
NOTE: Use low-pressure air to push the piston out of the clutch. Take care to avoid damaging the piston.
g. Remove and discard square-ring seal (34) from piston (31). Remove and discard o-ring (35) from inside cylinder (33). These must be replaced with new parts during assembly.
h. Repeat steps a through g to disassemble the remaining clutch assembly.
Assemble Clutch Stack
1. Assemble clutch assemblies (12) and (13) as follows:
a. Set steel ball (32) in place inside cylinder (33).
NOTE: If cylinder (33) is being replaced with a new part, strike ball (32) one time with a punch. This will create a seat for the ball inside the cylinder.
b. Install a new o-ring (35) on the collar inside cylinder (33).
c. Install a new square-ring seal (34) on piston (31). Lubricate the piston with a light coat of oil.
d. Install piston (31) into the cylinder. Press the piston into place with the special tool to make sure it is fully installed.
e. Set spring (30) and retainer (29) in place on top of the piston.
f. Set the special tool over spring retainer (29). Use a hydraulic press to compress the spring enough to install snap ring (28). Make sure the snap ring is completely seated in its groove in the piston collar before releasing hydraulic pressure.
g. Set one steel separator plate (27) into the clutch. Make sure the "dished" side of the plate faces up.
NOTE: Separator plates (27) are missing teeth at two points. Orient the plates in the clutch so that these missing teeth line up with two of the oil slots inside cylinder (33).
h. Install one bronze clutch plate (26) on top of separator plate (27).
i. Alternate separator plates (27) and clutch plates (26) until six of each have been installed. The last plate to go in will be a bronze clutch plate (26).
j. Repeat steps a through h to assemble the remaining clutch assembly.
2. If removed, install bearing (28) onto output shaft (10). Install snap ring (25) to secure the bearing.
3. Install one thrust bearing (19) and pilot bearing (18) on output shaft (10).
4. Install output gear (17), with gear teeth facing down, onto the output shaft. Make sure pilot bearing (18) fits inside the output gear bore.
5. Install a second thrust bearing (19) on top of the output gear.
6. Orient rear clutch hub (16) as shown, and install onto the output shaft. Make sure the internal spline of the clutch hub engages the external spline on the output shaft.
NOTE: Rear clutch hub (16) and front clutch hub (9) appear similar, but have different size internal splines. If the clutch hub does not fit correctly, they may have been switched.
7. Install snap ring (15) onto the output shaft to secure rear clutch hub (16). Make sure the snap ring fits tightly into its groove in the output shaft.
8. Make sure output gear (17) rotates smoothly on the output shaft.
9. Insert the output shaft assembly into rear clutch assembly (13). Support the weight of the output shaft and rotate back and forth during installation. This will align the clutch plate splines with the splines of rear clutch hub (16).
10. Install snap ring (14) into rear clutch assembly (13). This will secure the clutch assembly to the output shaft.
11. Install front clutch assembly (12) onto the output shaft, against rear clutch assembly (13). Make sure the front clutch is oriented as shown.
12. Install snap ring (11) to the output shaft, inside the front clutch assembly. This snap ring should fit somewhat loosely in its groove on the output shaft.
13. Orient front clutch hub (9) as shown, and install into front clutch assembly (12). Rotate the clutch assembly back and forth during installation. This will align the clutch plate splines with the splines of the front clutch hub.
14. Install thrust bearing (8) and pilot bearing (7) onto the output shaft, on top of front clutch hub (9).
15. If removed, install bearing (6) onto input shaft (4). Make sure the bearing is seated squarely against the gear at the end of the shaft.
16. Apply a light coat of oil to two seals rings (21) at the end of output shaft (10). Center the rings on the shaft. This will make it easier to install the input shaft in the following step.
17. Slide input shaft (4) over the output shaft, into the front clutch assembly.
18. Install snap ring (3) into the front clutch assembly. This will secure the input shaft to the clutch stack. Make sure the snap ring fits tightly in its groove.
19. Make sure front clutch assembly (12) and rear clutch assembly (13) both rotate freely on the clutch stack.
20. Install shims (2), if used, and adapter ring (1) on the output end of the clutch stack. Seat these parts against the snap ring of bearing (24).