Special Tools

1. Using J 28585 remove the 4-5 clutch backing plate retaining ring (575) from the 4-5 clutch drum assembly (584).
2. Remove the following components from the 4-5 clutch drum assembly (584):

•	The 4-5 clutch backing plate (576)

•	The 4 fiber plates (577)

•	The 4 steel plates (578)




3. Remove the 4-5 clutch piston return spring assembly (580).

3.1.	Place the J 25024-A  (3) in a vise with the forcing screw on the bottom and backed out.

3.2.	Place the J 45186  (1) on the 4-5 clutch piston return spring assembly (580).

3.3.	Place the J 21420-2  (4) from the J 23327 on top of the forcing screw of J 25024-A  (3).

3.4.	Place the clutch housing with the J 45186  (1) on the J 21420-2 (4) and under the arms of J 25024-A  (3).

3.5.	With the forcing screw, compress the clutch spring to allow the removal of the retaining ring.

3.6.	Use J 28585  (2) or snap ring pliers to remove the retaining ring (579).

4. Remove the 4-5 clutch piston return spring assembly (580).




Warning: Wear safety glasses when using compressed air in order to prevent eye injury.

5. Using the case as a holding fixture, install the front differential transfer drive gear assembly (14) into the output gear bore.
6. Install the 4-5 clutch assembly (15) onto the front differential transfer drive gear assembly (14), with the clutch piston facing up, so that the fluid passages are around the sealing rings.



7. Apply air pressure to the fluid passage (1) in the end of the front differential transfer drive gear assembly shaft and remove the 4-5 clutch piston assembly (582).
8. Remove the 4-5 clutch drum assembly and the front differential transfer drive gear assembly from the case.



9. Remove the piston inner seal (581) and the piston outer seal (583) from the 4-5 clutch piston (582).

Special Tools

J 45185 Bore Gage Set

1. Wash the clutch components in clean solvent and air dry.
2. Inspect the clutch drum for the following conditions:

•	Lugs in the drum for excessive grooves that prevent the clutch plates from sliding

•	Sun gear for chips or metal embedded in the teeth

•	Drum surface for scoring or excessive wear

•	Piston o-ring surfaces for wear, nicks, or scratches

•	Bearing thrust surfaces for damage or wear

3. Using J 45185 , measure the inner diameter of the 4-5 clutch drum bushing (A) at different locations and take the average.

Specification
36.125 - 36.200 mm (1.422 - 1.425 in)

4. If the bushing is out of specifications or any of the above conditions are found replace the 4-5 clutch drum



5. Shake the clutch piston to inspect the ball check valve for not being stuck.
6. Apply compressed air in the opposite side of the check valve and inspect for leaking.
7. Inspect the piston o-ring seal grooves for damage.
8. Replace the piston if any of the above conditions are found.
9. Inspect the clutch plates and discs for wear, warp age, or being burnt.
10. Replace the clutch plates and discs if any of the above conditions are found.