4. Forward Clutch Disassemble & Service

Clutch Disassembly

Special Tools Required
^ Clutch spring compressor attachment 07LAE-PX40100
^ Clutch spring compressor attachment 07HAE-PL50101
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A





1. Remove the snap ring (A), then remove the clutch end plate, the clutch discs, and the plates with a screwdriver (B).





2. Remove the disc spring.





3. Install the special tool on the clutch assembly.





4. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the clutch.





5. If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.





6. Compress the spring until the snap ring can be removed.





7. Remove the snap ring (A). Then remove the special tools (B), spring retainer (C), and return spring.





8. Wrap a shop rag around the clutch drum (A), and apply air pressure to the fluid passage to remove the piston (B). Place a finger tip on the other end while applying air pressure.

Clutch Inspection





1. Inspect the clutch piston and clutch piston check valve. If the clutch check valve is loose or damaged, replace the clutch piston.
2. Check the spring retainer for wear and damage.
3. Inspect the clutch discs, clutch plates, and clutch end plate for wear, damage, and discoloration.
^ If the clutch discs are worn or damaged, replace the disc and plates as a set.
^ If the clutch plates are worn, damaged, or discolored, replace the discs and plates as a set.
^ If the clutch end plate is worn, damaged, or discolored, inspect the clutch end plate-to-top disc clearance, then replace the clutch end plate.

Clutch Reassembly

Special Tools Required
^ Clutch spring compressor attachment 07LAE-PX40100
^ Clutch spring compressor attachment 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 piston (B).





3. Install the 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.





4. Install the return spring (A) and spring retainer (B), and position the snap ring (C) on the retainer.





5. Install the special tool.





6. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the clutches.





7. If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.





8. Compress the return spring.





9. Install the snap ring (A).
10. Remove the special tools.





11. Install the disc spring in the direction shown.





12. Starting with a clutch plate, alternately install the clutch plates and discs. Install the clutch end plate (A) with the flat side toward the disc (B).





13. Install the snap ring (A) with a screwdriver (B).





14. Verify that the snap ring end gap (A) is 7.9 mm (0.311 inch) or more.
15. Check that the clutch piston engages by applying air pressure to the fluid passage, and also check that the piston releases when released air pressure.





16. Set a dial indicator (A) on the clutch end plate (B).
17. Zero the dial indicator with the clutch end plate lifted up to the snap ring (C).





18. Release the clutch end plate to lower the clutch end plate, then put the special tool on the end plate (A).
19. Press the special tool down with 39 N (4 kgf, 9 lbs.) using a force gauge, and read the dial indicator (B). The dial indicator reads the clearance (C) between the clutch end plate and top disc (D). Take measurements in at least three places, and use the average as the actual clearance.
Clutch End-Plate-to-Top-Disc Clearance Service Limit: 0.6 - 0.8 mm (0.024 - 0.031 inch)








20. If the clearance is out of the service limit, select a new clutch end plate from the following table, then recheck.

NOTE: If the thickest clutch end plate is installed, but the clearance is still over the standard, replace the clutch discs and clutch plates.

21. After replacing the clutch end plate, make sure that the clearance is within tolerance.