Forward Clutch: Assembly

Inspect the clutch components for damage or wear. Install new components as necessary.
- Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
- Inspect the clutch plates for damage.
- Inspect the clutch springs.
- Inspect the needle bearing and seal rings for damage.
- Check clutch hub thrust surfaces for damage.
- Check clutch plates for flatness and fit on the clutch hub serrations.
NOTE: If the seals on the forward clutch piston show any signs of damage, a new forward clutch piston will need to be installed.
Inspect the forward clutch piston and seals.

Fig 1: Locating Forward Clutch Piston And Seals
Inspect the forward clutch drum assembly.
1. Inspect the forward clutch cylinder surfaces for scores or burrs.
2. Inspect the forward clutch piston for scores or burrs.
3. Verify the check ball is free to move in the piston.
  
  Fig 2: Locating Forward Clutch Cylinder Surfaces
NOTE: The special tool must be installed on the forward clutch piston for a couple of minutes prior to installing it into the forward clutch cylinder.
Install the special tool on the forward clutch piston.

Fig 3: Identifying Special Tool

CAUTION: Care must be taken to prevent damage to the seals.

NOTE: Lubricate the forward clutch piston inner and outer seal with clean automatic transmission fluid.
Using the special tool, install the forward clutch piston assembly into the forward clutch cylinder.

Fig 4: Identifying Special Tool
Install the forward clutch piston spring assembly.

Fig 5: Locating Forward Clutch Piston Spring Assembly

CAUTION: Do not fully depress the clutch spring compressor or damage to the spring retainer may occur.
Using the special tool, install the forward clutch piston spring retaining ring.

Fig 6: Identifying Forward Clutch Piston Spring Retaining Ring

CAUTION: The forward clutch friction plates are directional and must be installed with grooves pointing counterclockwise.

CAUTION: If new plates are used, they should be soaked in clean automatic transmission fluid before assembly.
If reusing plates, grooves must be installed counterclockwise. Install the direct clutch disc pack.

Fig 7: Locating Forward Clutch Friction Plates Grooves
Install the steel clutch plates and friction clutch plates in alternating order starting with a steel clutch plate.

Fig 8: Identifying Steel Clutch Plates And Friction Clutch Plates

CAUTION: The retaining ring is a select fit.
Install the original selective retaining ring.
1. Install the forward clutch pressure plate.
2. Install the original selective retaining ring.
  
  Fig 9: Identifying Original Selective Retaining Ring
WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Make sure the cylinder is facing down as shown. Failure to follow these instructions may result in personal injury.
Air check the forward clutch piston.
1. Place the forward clutch cylinder with forward clutch piston facing down.
2. Install the transmission center support on the forward clutch cylinder.
3. Apply air pressure to the left port of the center support.
  
  Fig 10: Identifying Left Port Of Center Support

Check the forward clutch disc pack free play.

Press down on the forward clutch disc pack.
Using a feeler gauge, check the gap between the forward clutch retaining ring and the forward clutch pressure plate.

If the clearance is not within specifications, install the correct size retaining ring.

THICKNESS SPECIFICATIONS

Part Number	Thickness		Diameter
Part Number	mm	In	mm	In
XW4Z-7D483-AB	1.73	0.0681	141.45	5.65
XW4Z-7D483-AC	2.08	0.0819	141.45	5.65
XW4Z-7D483-AD	2.44	0.0961	141.45	5.65

Fig 11: Identifying Gap Between Forward Clutch Retaining Ring And Forward Clutch Pressure Plate