5. Clutch Assembly

CLUTCH ASSEMBLY
Preparation





Special Service Tools

Preinspection
Reverse, Forward, Coasting Clutch Operation





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

Air pressure: 390 kPa (4.0 kgf/cm2, 57 psi) max.

Clutch Clearance
Reverse Clutch





1. Measure the clearance between the retaining plate and the drive plate. Make several measurements and calculate the average value.

Clearance: 1.5 - 1.8 mm (0.059 - 0.071 inch)

2. If 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. Make several measurements and calculate the average value.

Clearance: 1.0 - 1.2 mm (0.039 - 0.047 inch)

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. Make several measurements and calculate the average value.

Clearance: 1.0 - 1.2 mm (0.039 - 0.047 inch)

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

Disassembly/Inspection/Assembly





1. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Assemble in the reverse order of disassembly, referring to ASSEMBLY PROCEDURE.

Disassembly Note
Snap Ring (Coasting Clutch)

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 assembly.
3. Remove the snap ring.
4. Remove the SSTs, and remove the spring and retainer assembly.

Coasting Clutch Drum





1. Set the reverse and forward drum onto the oil pump.
2. Remove the coasting clutch drum from the reverse and forward drum by applying compressed air through the fluid passage.

Air pressure: 390 kPa (4.0 kgf/cm2, 57 psi) max.

Coasting Clutch Piston





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 (Reverse Clutch)

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 groove with snap ring pliers.





4. Remove the SSTs from the reverse and forward drum.
5. Remove the snap ring.

Reverse Piston





1. Set the reverse and forward drum onto the oil pump.
2. Remove the reverse piston by applying compressed air through the fluid passage.

Air pressure: 390 kPa (4.0 kgf/cm2, 57 psi) max.

Inspection
Drive Plates





1. Measure the facing thickness in three places and calculate the average value.

Standard: 1.6 mm (0.063 inch)
Minimum: 1.4 mm (0.055 inch)

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

Spring And Retainer Assembly





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

Free length: 31.54 mm (1.242 inch)

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

Coasting Clutch 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: 390 kPa (4.0 kgf/cm2, 57 psi) max.

3. Replace the coasting clutch piston if damaged or malfunctioning.

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: 390 kPa (4.0 kgf/cm2, 57 psi ) max.

3. Replace the reverse piston if damaged or malfunctioning.

Assembly Procedure
Reverse Clutch





1. 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: 160.5 mm (6.319 inch)
Outer seal: 188.0 mm (7.402 inch)





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.





2. Install the piston return spring with the tabs facing upward.
3. Install the return spring stopper with the step facing upward.





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





5. 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.

6. Compress the piston return spring assembly.





7. Install the snap ring.
8. Remove the SST.
9. Install the drive and driven plates in the following order.
Driven-Drive-Driven-Drive
10. Install the retaining plate.
11. Install the snap ring.





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

Reverse clutch clearance: 1.5 - 1.8 mm (0.059 - 0.071 inch)





Snap Ring Sizes

Coasting Clutch





1. 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: 71.02 mm (2.796 inch)
Outer seal: 137.0 mm (5.394 inch)

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 coasting clutch drum into the reverse and forward drum as shown.





2. 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: 122.02 mm (4.804 inch)





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.





3. Install the spring and retainer assembly.
4. 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.





5. Compress the spring and retainer assembly.
6. Install the snap ring.
7. Remove the SSTs.





8. Install the dished plate with the dished side facing upward.
9. Install the drive and driven plates in the following order.
Driven-Drive-Driven-Driven-Drive
10. Install the retaining plate.
11. Install the coasting clutch snap ring in the direction shown in the figure.





12. 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 specification, adjust it by selecting a proper snap ring from below.

Coasting clutch clearance: 1.0 - 1.2 mm (0.039 - 0.047 inch)





Snap Ring Sizes

Forward Clutch





1. Install the dished plate with the dished side facing downward.
2. Install the drive and driven plates in the following order. Driven-Drive-Driven-Drive-Driven-Drive





3. Install the retaining plate.
4. Install the forward clutch snap ring in the direction shown in the figure.





5. 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 specification, adjust it by selecting a proper snap ring from below.

Forward clutch clearance: 1.0 - 1.2 mm (0.039 - 0.047 inch)





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: 390 kPa (4.0 kgf/cm2, 57 psi) max.





7. Apply petroleum jelly to the thrust bearings, and secure them onto the reverse and forward drum.

Thrust bearing outer diameter
Oil pump side: 86.0 mm (3.39 inch)
Small sun gear and one-way clutch side: 56.1 mm (2.21 inch)