Forward Clutch

DISASSEMBLY





1. CHECK PISTON STROKE OF FORWARD CLUTCH
a. Install the forward clutch on the oil pump.

NOTICE: Be careful not to damage the oil seal ring of oil pump.

b. Using a dial indicator, measure the forward clutch piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Piston stroke: 2.09 - 2.23 mm (0.0823 - 0.0878 inch)
If the clearance is non-standard, inspect the discs, plates flange.

HINT: As the opening is big, cover it with a shop rug as well as an compressed air to prevent the air from discharging.

2. REMOVE FLANGE, PLATE AND DISC





a. Using a screwdriver, remove the snap ring from the forward clutch drum.





b. Remove the flange, 6 discs and 6 plates.
3. REMOVE PISTON RETURN SPRING





a. Place Special Service Tool (SST) on the spring retainer and compress the return spring with a press.
SST 09350-32014 (09351-32070)
b. Using a snap ring expander, remove the snap ring.





c. Remove the piston return spring.





4. REMOVE FORWARD CLUTCH PISTON
a. Place the forward clutch drum onto the oil pump.
b. Holding the forward clutch piston with your hard, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil pump to remove the forward clutch piston.

HINT: When the piston can not be removed as it is slanted, either blow the air again with the protruding side pushed or remove the piston using the needle nose pliers with vinyl tape on the tip.





5. REMOVE O-RING
Using a small screwdriver, remove the 2 O-rings.

INSPECTION





1. INSPECT DISC, PLATE AND FLANGE
Check to see if the sliding surface of the disc, plate and flange are worn or burnt.
If necessary, replace them.

HINT:
- If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs.
- Before assembling new discs, soak them in ATF for at least 15 minutes.

2. CHECK FORWARD CLUTCH PISTON





a. Shake the piston to check that the check ball is not stuck.





b. Check that the valve does not leak when applying low compressed air (392 kgf/cm2, 4.0 pKa, 57 psi).





3. CHECK FORWARD CLUTCH PISTON RETURN SPRING
Using a vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 28.23 mm (1.1114 inch)





4. CHECK MULTIPLE DISC CLUTCH HUB BUSHING
Using a dial indicator, measure the inside diameter of the forward clutch hub bushing.
Standard inside diameter: 23.03 - 23.04 mm (0.9067 - 0.9071 in.)
Maximum inside diameter: 23.09 mm (0.9091 inch)

NOTICE:
- When the diameter is over the maximum, replace the multiple disc clutch hub with new one.
- Check the contact surface of the bush in the direct clutch shaft. If any scratch or discolor is identified, replace the direct clutch subassembly with new one.

If the inside diameter is greater than the maximum, replace the forward clutch hub.

REASSEMBLY
1. INSTALL FORWARD CLUTCH PISTON





a. Coat 2 new O-rings with ATF, and install them to the forward clutch piston.





b. Install the forward clutch piston to the forward clutch drum.
2. INSTALL PISTON RETURN SPRING





a. Place the return spring onto the piston.





b. Place Special Service Tool (SST) on the return spring, and compress the return spring with a press.
SST 09350-32014 (09351-32070)
c. Install the snap ring with a snap ring expander. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

NOTICE:
- Stop the press when the spring sheet is lowered to the place 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove, preventing the spring sheet from the deforming.
- Do not expand the snap ring excessively.





3. INSTALL PLATE, DISC AND FLANGE
Install the 6 plates and 6 discs in order.
Install in order: P = Plate, D = Disc, F = Flange P-D-P-D-P-D-P-D-P-D-P-D-F





4. INSTALL SNAP RING
a. Using a screwdriver, install the snap ring.
b. Check that the end gap of the snap ring is not aligned with one of the cutouts.
5. CHECK PISTON STROKE OF FORWARD CLUTCH





a. Using a dial indicator, measure the forward clutch piston stroke while applying and releasing compressed air (392 kgf/cm2, 4.0 kPa, 57 psi).
Piston stroke: 2.09 - 2.23 mm (0.0823 - 0.0878 inch)
If the piston stroke is less than the limit, parts may have been assembled incorrectly, check and reassemble again.
If the clearance is non-standard, select another flange.

HINT: There are 5 different flanges in thickness.





Flange thickness





6. CHECK DISK ROTATE
Check that the disc lightly rotates when rotating the forward clutch assembly after inserting the multiple disc clutch into it.

NOTICE: Do not place the forward clutch assembly in a vise.