Dog Clutch F Disassembly And Assembly

WARNING:

Always wear safety glasses when cleaning, disassembling and assembling the transmission/transaxle. Contents of the transmission/transaxle can become projectiles (e.g., springs, snap-rings, as well as metal and other debris). Failure to wear safety glasses may result in severe personal injury.

NOTE:

The dog clutch F is located in the output gear support.

NOTE:

There are no adjustments to be made for dog clutch F.

DISASSEMBLY

Clamp the output gear support assembly in a suitable bench vise.

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1 - Staking
Using a suitable screwdriver, pry the staking in the locking plate outward to allow to stake nut to rotate.

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1 - Wrench, Spanner 2012900210

2 - Stake Nut

Using tool, remove the stake nut holding the output gear and bearing to the output gear support hub.

(Special tool #2012900210, Wrench, Spanner)

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1 - Lock Plate

2 - Output Gear

3 - Output Gear Support Hub

Remove the lock plate from the output gear support.

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1 - Output Gear

2 - Output Gear Support Hub

Remove the output gear from the output gear support hub.

NOTE:

The double roller bearing in the output gear cannot be removed. If the bearing is damaged, replace the output gear.

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1 - Slide Hammer, Universal C-637

2 - Remover, Seal 7794-A

3 - Dog Clutch F Thrust Plate

Using tool, remove the dog clutch F thrust plate from the output gear support hub.
(Special tool #C-637, Slide Hammer, Universal) and (Special tool #7794-A, Remover, Seal)

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1 - Snap-Ring

2 - Output Gear Support Hub

Using a suitable screwdriver, remove the snap-ring holding the dog clutch F plug and piston in the output gear support hub.

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1 - Rubber Tipped Blow Gun

2 - Fluid Transfer Tube

3 - Output Gear Support Hub

4 - Dog Clutch F Piston And Plug

Place the fluid transfer tube into port shown in output gear support hub.
CAUTION:
Do not exceed 138 kPa (20 psi) or damage may occur.

NOTE:
Place a shop towel over the dog clutch F and plug prior to applying air.
Using an air supply regulated to 138 kPa (20 psi) and a rubber tipped blow gun, remove the dog clutch F piston and plug from the output gear support hub.

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1 - Dog Clutch F Plug

2 - O-Ring
Remove the dog clutch F plug from the dog clutch F piston.
Remove the O-ring seal from the inside of the dog clutch F plug.

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1 - Dog Clutch F Piston

2 - O-Ring

3 - Tool
Using a suitable tool, remove the outer O-ring seal from the dog clutch F piston.

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1 -O-Ring

2 - Dog Clutch F Piston
Remove the inner O-ring seal from the dog clutch F piston.

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1 - O-Ring

2 - Output Gear Support Hub
Remove the upper O-ring seal from the groove inside the output gear support hub.

ASSEMBLY

NOTE:

Clean the dog clutch F assembly components with solvent and blow them dry with regulated 344 kPa (50 psi) shop air. Inspect the dog clutch F assembly components for damage or excessive wear. If dog clutch F assembly components are damaged the entire output gear support assembly will require replacement. Only the O-ring seals can be replaced. Apply assembly lubricant to the O-ring seals to aid installation.

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1 -O-Ring

2 - Output Gear Support Hub

Install a NEW upper O-ring seal into the groove inside the output gear support hub.

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1 - Dog Clutch F Piston

2 - O-Ring
Install a NEW inner O-ring seal into the dog clutch F piston.

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1 - Dog Clutch F Piston

2 - O-Ring
Install a NEW outer O-ring seal onto the dog clutch F piston.

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1 - Dog Clutch F Plug

2 - O-Ring
Install a NEW O-ring seal into the inside of the dog clutch F plug.

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1 - Dog Clutch F Piston

2 - Output Gear Support Hub
Install the dog clutch F piston into the output gear support hub to the bottom of the bore.

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1 - Dog Clutch F Plug

2 - Output Gear Support Hub
Install the dog clutch F plug onto the dog clutch F piston in the output gear support hub, with the chamfered outer edge down.

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1 - Dog Clutch F Plug

2 - Output Gear Support Hub
Push the dog clutch F plug into the bore until it bottoms against the top of the spline in the output gear support hub.

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1 - Snap-Ring

2 - Output Gear Support Hub
Install the snap-ring to hold the dog clutch F assembly plug and piston in the output gear support hub.

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1 - Dog Clutch F Thrust Plate

2 - Output Gear Support Hub

Place the dog clutch F thrust plate with stepped side down, into the output gear support hub.

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1 - Driver Handle, Universal C-4171

2 - Cup 8148

3 - Output Gear Support Hub

Using the tools mentioned below, install the dog clutch F assembly thrust plate into the output gear support hub.
(Special tool #8148, Cup) and (Special tool #C-4171, Driver Handle, Universal)

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1 - Output Gear

2 - Output Gear Support Hub

Install the output gear onto the output gear support hub.

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1 - Lock Plate

2 - Output Gear

3 - Output Gear Support Hub Notch

Align the tab on the lock plate with the notch on the output gear support hub and install the lock plate onto the output gear.

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1 - Wrench, Spanner 2012900210

2 - Stake Nut
Using tool mentioned below, install the stake nut to hold the output gear and bearing to the output gear support hub and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .
(Special tool #2012900210, Wrench, Spanner)

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1 - Staking
Using a suitable punch, stake the locking plate inward to lock the stake nut in position.
Install the output gear support in the transmission.