Clutch Assembly

SST:

Preparation

Preinspection




Clutch operation
1. Set the clutch assembly onto the oil pump.
2. Check the clutch operation by applying compressed air through the fluid passages shown.

Applied air pressure: 392 kPa {4.0 kg/sq.cm, 57 psi} max.




Clutch clearance

Reverse clutch
1. Measure the clearance between the retaining plate and the snap ring.

Clearance: 1.0 - 1.3 mm {0.039 - 0.051 in}

2. It not as specified, replace parts as necessary.
3. Select and install the correct snap ring when assembling.




Forward clutch
1. Measure the clearance between the retaining plate and the snap ring.

Clearance: 1.0 - 1.2 mm {0.039 - 0.047 in}

2. If not as specified, replace parts as necessary.
3. Select and install the correct snap ring when assembling.




Coasting clutch
1. Remove the snap ring, retaining plate, drive plates, driven plates and dished plate of the forward clutch.
2. Measure the clearance between the retaining plate and the snap ring.

Clearance: 1.0 - 1.2 mm {0.039 - 0.047 in}

3. If not as specified, replace parts as necessary.
4. Select and install the correct snap ring when assembling.




Disassembly / Inspection / Assembly
1. Disassembly in the order shown in the figure, referring to Disassembly Note.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in the reverse order of disassembly, referring to Assembly Procedure.

Disassembly note




Snap ring (coasting clutch)
1. Install the SST in the coasting clutch drum as shown.
2. Compress the spring and retainer assembly.
3. Remove the snap ring.
4. Remove the SST, then remove the spring and retainer assembly.




Coasting clutch drum
Remove the coasting clutch drum from the reverse and forward drum by applying compressed air through the fluid passage.




Coasting piston
Remove the coasting clutch piston from the coasting clutch drum by applying compressed air through the fluid passage.

Snap ring (reverse clutch)




1. Install the SST in the reverse and forward drum as shown.
2. Compress the piston return spring.




3. Remove one end of the snap ring from the groove with snap ring pliers.




4. Remove the SST from the reverse and forward drum.
5. Remove the snap ring with a screwdriver.




Reverse piston
1. Place the reverse and forward drum on the oil pump.
2. Remove the reverse piston by applying compressed air through the fluid passage.

Inspection




Drive plates
1. Measure the facing thickness in three places, and determine the average of the three readings.

Standard: 1.6 mm {0.063 m}
Minimum: 1.4 mm {0.055 in}

2. If not within specification, replace the drive plates.




Spring and retainer assembly
1. Measure the spring free length and check for deformation.

Free length: 20.45 mm {0.805 in}

2. If not within specification, replace the spring and retainer assembly.




Reverse piston
1. Verify that there is no air leakage when applying compressed air through the oil hole opposite the return spring.
2. Verify that there is air flow when applying compressed air through the oil hole on the return spring side.

Air pressure: 392 kPa {4.0 kg/sq.cm, 57 psi) max.




Coasting piston
1. Verify that there is no air leakage when applying compressed air through the oil hole opposite the return spring.
2. Verity that there is air flow when applying compressed air through the oil hole on the return spring side.

Air pressure: 392 kPa (4.0 kg/sq.cm, 57 psi) max.




Reverse and forward drum
1. Verify that there is no air leakage when applying compressed air through the oil hole opposite the return spring.
2. Verify that there is air flow when applying compressed air through the oil hole on the return spring side.

Air pressure: 392 kPa (4.0 kg/sq.cm, 57 psi) max.

Assembly procedure

Reverse clutch
1. Install the reverse piston.




1. Apply ATF to inner and outer faces of the seals, and install them to the reverse piston.
2. Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the reverse clutch drum.




3. Install the reverse piston by pushing evenly around the circumference, being careful not to damage the seal rings.




2. Install the piston return spring with the tabs facing away from the reverse piston.
3. Install the return spring stop with the step facing upward.




4. Install the snap ring half-way down the reverse forward drum as shown.




5. Install the SST on the reverse and forward drum.
6. Compress the spring and retainer assembly.
7. Install the snap ring with a screwdriver.
8. Remove the SST.




9. Install the dished plate with the dished side facing the piston as shown.
10. Install the drive and driven plates.

NOTE: Installation order: Driven-Drive-Driven-Drive

11. Install the retaining plate.
12. Install the snap ring.




13. Measure the reverse clutch clearance.
1. Measure the clearance between the snap ring and the retaining plate of the reverse clutch.
2. If the clearance is not within specification, adjust it by selecting a proper snap ring.

Reverse clutch clearance: 1.0 - 1.3 mm {0.039 - 0.051 in}

Snap Ring Sizes:

Snap Ring Sizes

Coasting clutch




1. Install the coasting clutch drum.
1. Apply ATF to inner and outer faces of the seal, and install it onto the coasting clutch drum.
2. Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the drum.




3. Install the coasting clutch drum in the correct position in the reverse and forward drum as shown.
4. Push evenly around the circumference, being careful not to damage the outer seal.

2. Install the coasting piston.




1. Apply ATF to inner and outer faces of the seals and install them onto the coasting piston.
2. Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the drum.




3. Install the coasting piston by pushing evenly around the circumference being careful not to damage the outer seal.




3. Install the spring and retainer assembly.




4. Install the SST in the coasting clutch as shown.
5. Compress the spring and retainer assembly.
6. Install the snap ring.
7. Remove the SST.




8. Install the dished plate with the dished side downward.

NOTE: Installation order: Driven-Drive-Driven-Drive

9. Install the drive and driven plates.
10. Install the retaining plate.
11. Install the snap ring.




12. Measure the coasting clutch clearance.
1. Measure the clearance between the snap ring and the retaining plate of the coasting clutch.
2. If the clearance is not within specification, adjust it by selecting a proper snap ring.

Coasting clutch clearance: 1.0 - 1.2 mm {0.039 - 0.047 in}

Snap Ring Sizes:

Forward clutch




1. Install the dished plate with the dished side downward.

NOTE:
- Installation order: Driven-Drive-Driven-Drive-Driven-Drive

2. Install the drive and driven plates.




3. Install the retaining plate.
4. Install the snap ring.




5. Measure the forward clutch clearance.
1. Measure the clearance between the snap ring and the retaining plate of the forward clutch.
2. If the clearance is not within specification, adjust it by selecting a proper snap ring.

Forward clutch clearance: 1.0 - 1.2 mm {0.039 - 0.047 in}

Snap Ring Sizes:

6. Check the clutch operation as follows.
1. Set the clutch assembly onto the oil pump.
2. Check the clutch operation by applying compressed air through the fluid passages shown.

Air pressure: 392 kPa {4.0 kg/sq.cm, 57 psi} max.




7. Apply petroleum jelly to the thrust bearings, and secure them on each side of the reverse and forward drum.

Thrust bearing outer diameter
Oil pump side: 86.0 mm {3.39 in}
Small sun gear and one-way clutch side: 56.1 mm {2.21 in}