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Direct Clutch Disassembly & Reassembly: Disassembly

  1. Prior to disassembly, check piston stroke of direct clutch. Measure piston stroke by applying 57-114 psi (4-8 kg/cm2 ) of compressed air. See Figure. Piston stroke should be .036-.053" (.91-1.35 mm) for A-540E and A-541E transaxles or .044-.058" (1.11-1.47 mm) for A-540H transaxle. If piston stroke is greater than maximum, inspect each component.
  2. Remove snap ring from clutch drum. Remove flange, discs and plates. Note number and location of components. See Figure. Compress piston return springs and remove snap ring. Remove spring retainer. Slide direct clutch onto oil pump. Remove piston by applying low pressure compressed air. See Figure. Remove direct clutch from oil pump. Remove "O" ring from clutch piston.
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