Part 2
Clutch Inspection1. Inspect the clutch pistons and the clutch piston check valves (A).
2. If the clutch piston check valve is loose or damaged, replace the clutch piston.
3. Check the spring retainer for wear and damage.
4. If the spring retainer is worn or damaged, replace it.
5. Check the oil seal (A) on the spring retainer of the 1st, 2nd, and 3rd clutches for wear, damage, and peeling.
6. If the oil seal is worn, damaged, or peeling, replace the spring retainer.
7. Inspect the clutch discs, the clutch plates, and the clutch end-plate for wear, damage, and discoloration.
8. If the clutch discs are worn or damaged, replace them as a set. If the clutch discs are replaced, inspect the clearance between the clutch end-plate and the top disc.
9. If any plate is worn, damaged, or discolored, replace the damaged plate with a new plate, and inspect the other wave-plates for a phase difference. If the clutch plate is replaced, inspect the clearance between the clutch end-plate and the top disc.
10. If the clutch end-plate is worn, damaged, or discolored, inspect the clearance the clutch end-plate and the top disc, then replace the clutch end-plate.
Clutch Wave-plate Phase Difference Inspection
1. Place the clutch wave-plate (A) on a surface plate, and set a dial indicator (B) on the wave-plate.
2. Find the bottom (C) of a phase difference of the wave-plate, zero the dial indicator and make a reference mark on the bottom of the wave-plate.
3. Rotate the wave-plate about 60-degrees apart from the bottom while holding the wave-plate by its circumference. The dial indicator should be at the top (D) of a phase difference. Do not rotate the wave-plate while holding its surface, always rotate it by holding its circumference.
4. Read the dial indicator. The dial indicator reads the phase difference (E) of the wave-plate between bottom and top.
Standard Phase Difference:
2nd Clutch: 0.10-0.20 mm
4th Clutch: 0.07-0.20 mm
5th Clutch: 0.07-0.20 mm
5. Rotate the wave-plate about 60-degrees. The dial indicator should be at the bottom of a phase difference (F and G), and zero the dial indicator.
6. Measure the phase difference at the other two tops (H and I) of the wave-plate by following steps 3 thru 5.
7. If two of the three measurements are within the standard, the wave-plate is OK. If two of the three measurements are out of the standard, replace the wave-plate.
Clutch Clearance Inspection
Special Tools Required
Clutch compressor attachment 07ZAE-PRP0100
1. Inspect the clutch piston, the discs, the plates, and the end-plate for wear and damage, and inspect the clutch wave-plate phase difference, if necessary.
2. Install the clutch piston in the clutch drum. Do not install the O-rings during inspection.
3. 1st clutch: Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch plate, alternately install the clutch plate (C) (5) and the discs (D) (5), then install the clutch end-plate (E) with the flat side toward the disc.
4. '04-05 models 2nd clutch: Install the waved spring (A) in the 2nd clutch drum (B). Install the 4.0 mm-thick plate (C) with the shear droop side (D) toward the inside of the drum, clutch disc (E), and the 2.0 mm-thick flat-plate (F), then starting with the disc, alternately install the discs (G) (4) and the wave-plates (H) (3), then install the clutch end-plate (I) with the flat side toward the disc.
5. '06-08 models 2nd clutch: Install the waved spring (A) in the 2nd clutch drum (B). Install the clutch flat-plate (C), then starting with the clutch disc, alternately install the discs (D) (6) and the clutch wave-plates (E) (5). Install the clutch end-plate (F) with the flat side down on the top disc.
6. '04-05 models 3rd clutch: Install the waved spring (A) in the 3rd clutch drum (B). Starting with the clutch plate, alternately install the clutch plate (C) (5) and the discs (D) (5), then install the clutch end-plate (E) with the flat side toward the disc.
7. '06-08 models 3rd clutch: Install the waved spring (A) in the 3rd clutch drum (B). Install the clutch flat-plates (C) (6), then starting with the clutch disc, alternately install the discs (D) (6). Install the clutch end-plate (E) with the flat side down on the top disc.
8. '04-05 models 4th clutch: Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch wave-plate, alternately install the clutch plates (C) (4) and the discs (D) (4), then install the clutch end-plate (E) with the flat side toward the disc.
9. '06-08 models 4th clutch: Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (4) and the discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
10. '04-05 models 5th clutch: Install the waved spring (A) in the 5th clutch drum (B). Starting with the clutch wave-plate, alternately install the clutch plates (C) (4) and the discs (D) (4), then install the clutch end-plate (E) with the flat side toward the disc.
11. '06-08 models 5th clutch: Install the waved spring (A) in the 5th clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (4) and the discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
12. Install the snap ring using a screwdriver to secure the clutch end-plate.
13. Set a dial indicator (A) on the clutch end-plate (B).
14. Zero the dial indicator with the clutch end-plate lifted up to the snap ring (C).
15. Release the clutch end-plate to lower the clutch end-plate, then put the clutch compressor attachment on the end-plate (A).
16. For 2nd, 4th, and 5th clutches: Press the clutch compressor attachment down with 150-160 N (15-16 kgf, 33-35 lbf) using a force gauge, and read the dial indicator (B).
17. For 1st and 3rd clutches: Press the clutch compressor attachment down with 39 N (4.0 kgf, 9 lbf) using a force gauge, and read the dial indicator.
18. The dial indicator reads the clearance (C) between the clutch end-plate and the top disc (D). Take measurements in at least three places, and use average as the actual clearance.
Clearance between Clutch-End-plate and Top Disc
Service Limit:
'04-05 Models:
1st Clutch: 0.82-1.02 mm (0.032-0.040 in.)
2nd Clutch: 0.88-1.08 mm (0.035-0.043 in.)
3rd Clutch: 0.82-1.02 mm (0.032-0.040 in.)
4th Clutch: 0.93-1.13 mm (0.037-0.044 in.)
5th Clutch: 0.93-1.13 mm (0.037-0.044 in.)
'06 Model:
1st Clutch: 0.82-1.02 mm (0.032-0.040 in.)
2nd Clutch: 1.18-1.38 mm (0.046-0.054 in.)
3rd Clutch: 1.00-1.20 mm (0.039-0.047 in.)
4th Clutch: 0.93-1.13 mm (0.037-0.044 in.)
5th Clutch: 0.93-1.13 mm (0.037-0.044 in.)
'07-08 Models:
1st Clutch: 0.82-1.02 mm (0.032-0.040 in.)
2nd Clutch: 1.14-1.34 mm (0.045-0.053 in.)
3rd Clutch: 1.00-1.20 mm (0.039-0.047 in.)
4th Clutch: 0.93-1.13 mm (0.037-0.044 in.)
5th Clutch: 0.93-1.13 mm (0.037-0.044 in.)
19. If the clearance is out of the service limit, select a new clutch end-plate from the following table.
20. Install a new clutch end-plate, and recheck the clearance. If the thickest clutch end-plate is installed, but the clearance is still over the service limit, replace the clutch discs and the plates.
Clutch Reassembly
Special Tools Required
^ Clutch spring compressor attachment 07LAE-PX40100 or 07HAE-PL50101
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A
1. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.
2. Install new O-rings (A) on the 4th and 5th clutch piston (B).
3. Install a new O-ring (A) in the 1st, 2nd, and 3rd clutch pistons (B), and install a new O-ring (C) on the clutch drums (D).
4. Install the clutch piston (A) in the clutch drum (B). Apply pressure and rotate to ensure proper seating. Lubricate the piston O-ring with ATF before installing. Do not pinch the O-ring by installing the piston with too much force.
5. Install the return spring (A) and the spring retainer (B), and position the snap ring (C) on the retainer.
6. Install the clutch spring compressor attachment and the clutch spring compressor bolt assembly.
7. Set the clutch spring compressor attachment (A) on the spring retainer (B) of the 1st, 2nd, and 3rd clutches in such a way that the clutch spring compressor compresses the clutch return spring (C).
8. Be sure the clutch spring compressor attachment (A) is adjusted to have full contact with the spring retainer (B) on the 4th and 5th clutches.
9. If either end of the clutch spring compressor attachment is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.
10. Compress the return spring.
11. Install the snap ring using snap ring pliers.
12. Remove the clutch spring compressor attachment and the clutch spring compressor bolt assembly.
13. 1st clutch: Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch plate, alternately install the clutch plates (C) (5) and the discs (D) (5), then install the clutch end-plate (E) with the flat side toward the disc.
14. '04-05 models 2nd clutch: Install the waved spring (A) in the 2nd clutch drum (B). Install the 4.0 mm-thick plate (C) with the shear droop side (D) toward the inside of the drum, the clutch disc (E), and the 2.0 mm-thick flat-plate (F), then starting with the disc, alternately install the discs (G) (4) and the wave-plates (H) (3), then install the clutch end-plate (I) with the flat side toward the disc.
15. '06-08 models 2nd clutch: Install the waved spring (A) in the 2nd clutch drum (B). Install the clutch flat-plate (C), then starting with the clutch disc, alternately install the discs (D) (6) and the clutch wave-plates (E) (5). Install the clutch end-plate (F) with the flat side down on the top disc.
16. '04-05 models 3rd clutch: Install the waved spring (A) in the 3rd clutch drum (B). Starting with the clutch plate, alternately install the clutch plates (C) (5) and the discs (D) (5), then install the clutch end-plate (E) with the flat side toward the disc.
17. '06-08 models 3rd clutch: Install the waved spring (A) in the 3rd clutch drum (B). Install the clutch flat-plates (C) (6), then starting with the clutch disc, alternately install the discs (D) (6). Install the clutch end-plate (E) with the flat side down on the top disc.
18. '04-05 models 4th clutch: Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch wave-plate, alternately install the clutch plates (C) (4) and the discs (D) (4), then install the clutch end-plate (E) with the flat side toward the disc.
19. '06-08 models 4th clutch: Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (4) and the discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
20. '04-05 models 5th clutch: Install the waved spring (A) in the 5th clutch drum (B). Starting with the clutch wave-plate, alternately install the clutch plates (C) (4) and the discs (D) (4), then install the clutch end-plate (E) with the flat side toward the disc.
21. '06-08 models 5th clutch: Install the waved spring (A) in the 5th clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (4) and the discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
22. Install the snap ring using a screwdriver to secure the clutch end-plate.
23. Check that the clutch piston moves by applying air pressure into the fluid passage.