Underdrive Clutch

OVERHAUL





1. INSPECT UNDERDRIVE PACK CLEARANCE
a. Install the U/D clutch to the transaxle case.

NOTICE: Be careful not to damage the oil seal rings.

b. Install a dial indicator as shown in the illustration.
c. Measure the U/D clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance: 1.51 - 1.71 mm (0.0594 - 0.0673 inch)
If the pack clearance is not within standard, inspect the discs, plates and flange.
2. REMOVE UNDERDRIVE CLUTCH DISC NO.1





a. Using a screwdriver, remove the U/D clutch flange No. 2 snap ring.





b. Remove the flange, 4 discs and 4 plates from the U/D clutch drum.





3. INSPECT UNDERDRIVE CLUTCH DISC NO.1
a. 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 comes off or discolors, or even if a part of the groove is defaced, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes.





4. INSPECT UNDERDRIVE CLUTCH DRUM SUB-ASSY
a. 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.
5. REMOVE UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSY





a. Place 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.
^ This prevents the spring sheet from being deformed.
^ Do not expand the snap ring excessively.





c. Remove the clutch balancer from the U/D clutch drum.





d. Remove the return spring from the U/D clutch drum.





6. INSPECT UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSY
a. Using a vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 17.14 mm (0.6752 inch)





7. REMOVE UNDERDRIVE CLUTCH PISTON SET
a. Install the U/D clutch to the transaxle case.

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

b. Holding the U/D clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove the U/D clutch piston.





8. REMOVE UNDERDRIVE CLUTCH DRUM O-RING
a. Using a screwdriver, remove the O-ring from the U/D clutch drum.





9. INSTALL UNDERDRIVE CLUTCH DRUM O-RING
a. Apply the new O-ring with ATF, install it to the U/D clutch drum.





10. INSTALL UNDERDRIVE CLUTCH PISTON SET
a. 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.
^ Be careful not to damage the lip seal of the piston.

11. INSTALL UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSY





a. Install the return spring to the U/D clutch drum.





b. Install the clutch balancer to the U/D clutch drum.

NOTICE: Be careful not to damage the lip seal of the clutch balancer.





c. Place SST on the clutch balancer and compress the piston return spring with a press.
SST 09350-32014 (09351-32070)
d. Using a snap ring expander, install the snap ring to the U/D clutch drum.
e. 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 grove.
^ This prevents the spring sheet from being deformed.
^ Do not expand the snap ring excessively.





f. Set the end gap of the snap ring in the U/D clutch drum shown in the illustration.

NOTICE: The end gap of the snap ring should not coincide with any of the stopper.

12. INSTALL UNDERDRIVE CLUTCH DISC NO.1





a. Apply the 4 discs with ATF.
b. Install the 4 plates, 4 discs and flange to the U/D clutch drum.





c. Using a screwdriver, install the U/D clutch flange No. 2 hole snap ring.
d. Check that the end gap of snap ring is not aligned with one of the cutouts.





13. INSPECT UNDERDRIVE PACK CLEARANCE
a. Install the U/D clutch to the transaxle case.

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

b. Set a dial indicator as shown in the illustration.
c. Measure the U/D clutch piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) .
Park clearance: 1.51 - 1.71 mm (0.0594 - 0.0673 inch)
If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble again.
If the pack clearance is not within standard, select another flange.

HINT: There are 5 flanges in different thickness.





Flange thickness: mm (in.)