Underdrive Clutch
DISASSEMBLY
1. CHECK PISTON STROKE OF U/D CLUTCH
a. Install the U/D clutch to the transaxle case.
NOTICE: Be careful not to damage the oil seal rings.
b. Install the dial indicator, as shown in the illustration.
c. Measure the U/D clutch piston stroke while applying and releasing compressed air (392 kgf/cm2, 4.0 kPa, 57 psi).
Piston stroke: 1.51 - 1.77 mm (0.0594 - 0.0697 inch)
If the piston stroke is non-standard inspect the discs, plates and flange.
2. REMOVE FLANGE, DISC AND PLATE
a. Using a screwdriver, remove the snap ring.
b. Remove the flange, 4 discs and 4 plates from the U/D clutch drum.
3. REMOVE PISTON RETURN SPRING
a. Place Special Service Tool (SST) on the clutch balancer and compress the spring with a press.
SST 09350-32014 (09351-32070)
b. Using a snap ring expander, remove the snap ring.
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 deforming.
- Do not expand the snap ring excessively.
c. Remove the clutch balancer and piston return spring from the U/D clutch drum.
4. REMOVE U/D CLUTCH PISTON
a. Install the U/D clutch to the transfer case.
NOTICE: Be careful not to damage the oil seal rings.
b. Holding the U/D clutch piston with your hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove the U/D clutch piston.
5. REMOVE O-RING
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 U/D CLUTCH DRUM BUSHING
Using a dial indicator, measure the inside diameter of the U/D clutch drum bushing.
Standard drum bushing: 37.06 - 37.08 mm (1.4591 - 1.4598 inch)
Maximum drum bushing: 37.13 mm (1.4618 inch) If the inside diameter is greater than the maximum, replace the U/D clutch drum.
3. CHECK U/D CLUTCH PISTON RETURN SPRING
Using vernier calipers, measure the free length of the spring together with spring seat.
Standard free length: 17.14 mm (0.6748 inch)
REASSEMBLY
1. INSTALL O-RING
Coat new O-ring with ATF, install it to the U/D clutch drum.
2. INSTALL U/D CLUTCH PISTON
Coat the U/D clutch piston with ATF, install it to the U/D clutch piston drum.
NOTICE: Be careful not to damage the O-ring.
3. INSTALL PISTON RETURN SPRING
a. Install the piston return spring and clutch balancer to the U/D clutch drum.
NOTICE: Be careful not to damage the lip seal of clutch balancer.
b. Place SST on the clutch balancer and compress the piston return spring with a press.
SST 09350-32014 (09351-32070)
c. Using a snap ring expander, install the snap ring to U/D clutch drum.
NOTICE:
- Be sure the end gap of the snap ring is not aligned with the clutch balancer claw.
- 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 deforming.
- Do not expand the snap ring excessively.
4. INSTALL PLATE, DISC AND FLANGE
a. Install the 4 plates, 4 discs and flange.
Install in order: P = Plate, D = Disc, F = Flange P-D-P-D-P-D-P-D-F
b. Using a screwdriver, install the snap ring.
c. Check that the end gap of snap ring is not aligned with one of the cutouts.
5. CHECK PISTON STROKE OF U/D CLUTCH
a. Install the U/D clutch to the transaxle case.
NOTICE: Be careful not to damage the oil seal rings.
b. Install the dial indicator, as shown in the illustration.
c. Measure the U/D clutch piston stroke while applying and releasing compressed air (392 kgf/cm2, 4.0 kPa, 57 psi).
Piston stroke: 1.51 - 1.77 mm (0.059 - 0.070 inch)
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.
HINT: There are 3 flanges in different thickness.
Flange thickness