Operation CHARM: Car repair manuals for everyone.
Home >> Mazda >> 2001 >> Millenia S V6-2.3L DOHC (Miller cycle) >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Service and Repair >> Unit Overhaul >> Forward Clutch Drum (Forward Clutch, Overrunning Clutch)

Forward Clutch Drum (Forward Clutch, Overrunning Clutch)

FORWARD CLUTCH DRUM (FORWARD CLUTCH, OVERRUNNING CLUTCH)
Preparation





SST

Preinspection
Forward Clutch, Overrunning Clutch Operation





1. Install the forward clutch drum in the drum support.
2. Apply compressed air through the oil passage as shown. Verify that the retaining plate move toward the snap ring.

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

Clutch Clearance





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

Clearance
Forward clutch 0.45 - 0.70 mm (0.018 - 0.028 inch)
Overrunning clutch: 0.7 - 1.1 mm (0.028 - 0.043 inch)

2. If not as specified, replace parts as necessary.
3. 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





1. Install the SST in the forward clutch as shown.
2. Compress the spring and retainer assembly.
3. Remove the snap ring.
4. Remove the SST, and remove the return spring and spring retainer.

Forward Clutch Piston, Overrunning Clutch Piston





1. Install the forward clutch drum in the transaxle case.
2. Remove the forward clutch piston from the forward clutch drum by applying compressed air through the fluid passage.

Air pressure: 390 kPa (4.0 kgf/CM2, 57 psi) max.





3. Remove the overrunning clutch piston from the forward clutch piston.

Inspection
Drive Plate





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

Forward clutch
Standard: 2.0 mm (0.079 inch)
Minimum: 1.8 mm (0.071 inch)

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





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

Return Spring And Retainer





1. Measure the spring free length,
2. If not as specified, replace the spring and retainer.

Overrunning 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 overrunning clutch piston if damaged or malfunctioning.

Forward Clutch Drum





1. Verify that there is no air leakage when applying compressed air through the oil hole opposite the low and reverse brake.
2. Verify that there is air flow when applying compressed air through the oil hole on the low and reverse brake side.

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

3. Replace the forward clutch drum if damaged or malfunctioning.

Assembly Procedure





1. Install the forward clutch piston.
1. Apply ATF to the inner and outer faces of the seals and install them to the forward clutch piston.

Seal ring inner diameter
Inner seal: 75.6 mm (2.976 inch)
Outer seal: 123.5 mm (4.862 inch)





2. Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the forward clutch drum.
3. Install the forward clutch piston by pushing evenly around the circumference, being careful not to damage the seal rings.





2. Install-the overrunning clutch piston.
1. Apply ATF to the inner and outer faces of the seals and install them to the overrunning clutch piston.

Seal ring inner diameter
Inner seal: 74.6 mm (2.937 inch)
Outer seal: 114.3 mm (4.500 inch)





2. Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into reverse clutch drum.
3. Install the overrunning clutch piston by pushing evenly around the circumference, being careful not to damage the seal rings.





3. Install the return spring and spring retainer.
4. Install the SST in the forward clutch.
5. Compress the return spring.
6. Install the snap ring.
7. Remove the SST.





8. Install the dish plate as shown.
9. Install the drive and driven plate of the overrunning clutch in the following order.
Driven-Drive-Driven-Driven-Drive-Driven-Driven-Drive
10. Install the retaining plate.
11. Install the snap ring.





12. Measure the overrunning clutch clearance.
1. Measure the clearance between the driven plate and the driven plate.





2. If the clearance is not within the specification, adjust it by selecting a proper retaining plate from below.

Overrunning clutch clearance: 0.7 - 1.1 mm (0.028 - 0.043 inch)





13. Install the dish plate to the forward clutch as shown.
14. Install the drive and driven plate in the following order.
Driven-Drive-Driven-Drive-Driven-Drive-Driven-Drive-Driven-Drive-Driven-Drive
15. Install the retaining plate.
16. Install the snap ring.
17. Measure the forward clutch clearance.





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





2. If the clearance is not within the specification, adjust it by selecting a proper retaining plate from below.

Forward clutch clearance: 0.45 - 0.85 mm (0.018 - 0.033 inch)





18. Install the forward clutch drum in the transaxle case.
19. Check the clutch operation by applying compressed air through the fluid passages shown.

Air pressure: 390 kPa (4.0 kgf/cm2, 57 psi) max.
pro multis · About Operation CHARM