Direct Clutch Assembly Assemble

Direct Clutch Assembly Assemble

Special Tools
* DT 46451 (DW240-020) Brake/Clutch Spring Compressor
* DT 46453 (DW240-040) Direct Clutch Adapter





Note: Do not expand the ring ends excessively.

1. Install the seal rings (1) to the input shaft.




2. Coat a new O-ring (1) with automatic transmission fluid (ATF) and install the O-ring to the input shaft.




3. Coat a new O-ring (1) with ATF and install the O-ring to the direct clutch piston.





Note: Do not damage the lip seal of direct clutch piston.

4. Coat the direct clutch piston with ATF, and install it to the direct clutch drum.




5. Install the direct clutch return spring.




6. Place DT 46451 (1) and DT 46453 (2) on the return spring and compress.

Note: Do not expand the snap ring excessively.

7. Using a snap ring expander, install the snap ring.





Note: Before installing the discs, coat them with ATF.

8. Install the 2 plates (2), 2 discs (3), and the flange (1) in order: 2-3-2-3-1.




9. Using a screwdriver, remove the snap ring.
10. Check that the end gap of the snap ring is not aligned with one of the cutouts.




11. Install the direct clutch on the oil pump.

Caution: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Caution (Compressed Air Should Not Exceed 98 kPa (14 psi) Caution).

12. Using a dial indicator, measure the direct clutch piston stroke while applying and releasing compressed air.

The piston stroke is 0.4-0.8 mm (0.016-0.031 in).

* If the piston stroke is less than the limit of piston stroke, parts may have been assembled incorrectly, so check and reassemble again.
* If the stroke is non-standard, select another flange.
* There are 3 flanges in different thickness.

- The number 1 flange thickness is 3 mm (0.118 in).
- The number 2 flange thickness is 3.2 mm (0.126 in).
- The number 3 flange thickness is 3.4 mm (0.134 in).