Clutch Component Disassembly/Assembly
CLUTCH COMPONENT DISASSEMBLY/ASSEMBLY1. Carry out the preinspection before disassembly.
2. Disassemble in the order indicated in the table.
3. Assemble in the reverse order of disassembly indicated in the table.
Snap ring disassembly note
Caution
^ Depress the piston return spring only enough to remove the snap ring. Overpressing will damage the retainer assembly edges.
1. Install the SSTs in the coasting clutch drum as shown.
2. Compress the spring and retainer.
3. Remove the snap ring.
4. Remove the SSTs, and remove the spring and retainer.
Coasting clutch drum disassembly note
1. Set the reverse and forward drum onto the oil pump.
2. Remove the coasting clutch piston from the reverse and forward drum by applying compressed air through the fluid passage.
Coasting clutch piston disassembly note
^ Remove the coasting clutch piston from the coasting clutch drum by applying compressed air through the fluid passage.
Air pressure
390 kPa (4.0 kgf/cm2, 57 psi) max.
Snap ring disassembly note
Caution
^ Depress the piston return spring only enough to remove the snap ring. Overpressing will damage the retainer assembly edges.
1. Install the SSTs in the reverse and forward drum as shown.
2. Compress the piston return spring.
3. Remove one end of the snap ring from the grove by using snap ring pliers.
4. Remove the SSTs from the reverse and forward drum.
5. Remove the snap ring.
Reverse piston disassembly note
^ Set the reverse and forward drum onto the oil pump. Remove the reverse piston by applying compressed air through the fluid passage.
Assembly procedure
1. Measure the facing thickness in three places and calculate the average value.
Standard:
1.6 mm (0.063 in)
Minimum:
1.4 mm (0.055 in)
2. If not within the specification, replace the drive plates.
3. Measure the free length of the spring and check for deformation.
4. If not within the specification, replace the spring and retainer.
5. Verify that there is no air leakage when applying compressed air through the oil hole opposite the return spring.
6. Verify that there is air flow when applying compressed air through the oil hole on the return spring side.
7. Replace the coasting clutch piston if it is damaged or malfunctioning.
8. Verify that there is no air leakage when applying compressed air through the oil hole opposite the return spring.
9. Verify that there is air flow when applying compressed air through the oil hole on the return spring side.
Air Pressure
390 kPa (4.0 kgf/cm2, 57 psi) max.
10. Replace the reverse piston if it is damaged or malfunctioning.
11. Verify that there is no air leakage when applying compressed air through the oil hole on the piston side.
12. Verify that there is air flow when applying compressed air through the oil hole opposite the piston side.
13. Replace the reverse and forward drum if it is damaged or malfunctioning.
14. Install the reverse piston.
1) Apply ATF to the inner and outer faces of the seals and install them to the reverse piston.
Seal ring inner diameter
Inner seal: 140.7 mm (5.539 in)
Outer seal: 164.3 mm (6.468 in)
2) Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the reverse and forward drum.
3) Install the reverse piston by pushing evenly around the circumference, being careful not to damage the seal rings.
15. Install the piston return spring with the tabs facing upward.
16. Install the return spring stopper with the step facing upward.
17. Install the snap ring half-way down the reverse and forward drum as shown.
18. Install the SST on the reverse and forward drum.
Caution
^ Depress the piston return spring only enough to install the snap ring. Overpressing will damage the retainer assembly edges.
19. Compress the piston return spring assembly.
20. Install the snap ring.
21. Remove the SST
22. Install the dished plate with the dished side facing downward.
23. Install the drive and driven plates in the following order.
Driven-Drive-Driven-Drive
24. Install the retaining plate.
25. Install the snap ring.
26. Measure the reverse clutch clearance.
1) Measure the clearance between the retaining plate and the drive plate.
Reverse clutch clearance
1.0 - 1.3 mm (0.039 - 0.051 in)
2) If the clearance is not within the specification, adjust it by selecting a proper snap ring from below.
Snap ring sizes
27. Install the coasting clutch drum.
1) Apply ATF to the inner and outer faces of the seals, and install them onto the coasting clutch drum.
Seal ring inner diameter
Inner seal: 56.1 mm (2.209 in)
Outer seal: 102.5 mm (4.035 in)
2) Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the reverse and forward drum.
3) Install the reverse piston by pushing evenly around the circumference, being careful not damage the seal rings.
28. Install the coasting clutch piston.
1) Apply ATF to the inner and outer faces of the seals and install them onto the coasting clutch piston.
Seal ring inner diameter
Outer seal: 115.4 mm (4.543 in)
2) Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the coasting clutch drum.
3) Install the coasting clutch piston by pushing evenly around the circumference, being careful not to damage the outer seal.
29. Install the spring and retainer assembly.
30. Install the SSTs in the coasting clutch.
Caution
^ Depress the piston return spring only enough to install the snap ring. Overpressing will damage the retainer assembly edges.
31. Compress the spring and retainer.
32. Install the snap ring.
33. Remove the SSTs.
34. Install the dished plate with the dished side facing upward.
35. Install the drive and driven plates in the following order.
36. Install the retaining plate.
37. Install the snap ring.
38. Measure the clearance between the retaining plate and the snap ring. Make several measurements and calculate the average value. If the clearance is not within the specification, adjust it by selecting a proper snap ring from below.
39. Install the dished plate with the dished side facing downward.
40. Install the drive and driven plates in the following order.
41. Install the retaining plate.
42. Install the snap ring.
43. Measure the clearance between the retaining plate and the snap ring. Make several measurements and calculate the average value. If the clearance is not within the specification, adjust it by selecting a proper snap ring from below.
44. Check the clutch operation as follows.
1) Set the clutch component onto the oil pump.
Caution
^ Applying compressed air to the assembled clutch pack for longer than 3 seconds at a time will damage the seal. Do not apply compressed air for more than the aforementioned time when testing the system.
2) Check the clutch operation by applying compressed air through the fluid passages shown.
45. Apply petroleum jelly to the thrust bearings, and secure them onto the reverse and forward drum.
Thrust bearing outer diameter
Oil pump side: 86.1 mm (3.390 in)
Small sun gear and one-way clutch side: 56.1 mm (2.21 in)