Assembly Procedure

Assembly Procedure





1. Apply ATF to the new O-rings and the intermediate shaft.
2. Install the O-rings to the intermediate shaft.

O-ring size





3. Apply ATF to the sliding surface of the C2 clutch piston.

Caution: Do not damage the seal on the piston and O-ring.





4. Install the C2 clutch piston to the intermediate shaft.
5. Apply ATF to the seal on the clutch balancer and sliding surface.

Caution:
^ Do not damage the seal on the clutch balancer.
^ Do not damage the O-ring.





6. Install the spring retainer, return spring and the clutch balancer to the intermediate shaft.

Caution: Be careful not to shorten the spring too much. If it is too short, it will bite into the O-ring.





7. Place the SST on the clutch balancer and compress the return spring with a press.

Caution: Do not expand the snap ring too much.

8. Install the snap ring into the groove using snap ring pliers.





9. Install the driven plates, drive plates and the retaining plate in the following order to the intermediate shaft as shown in the figure.

Three drive plates type
^ Driven-Drive-Driven-Drive-Driven-Drive-Retaining
Four drive plates type
^ Driven-Drive-Driven-Drive-Driven-Drive-Driven-Drive-Retaining





Caution: Inspect the number and order of the retaining plate, drive and driven plates.





10. Using a flathead screwdriver, install the snap ring into the groove.
11. Apply ATF to the thrust bearing.

Note: Install the bearing in the correct direction as shown in the figure.





12. Install the thrust bearing to the intermediate shaft.





13. Install the intermediate shaft on the transaxle case and set a dial indicator as shown in the figure.
14. Apply compressed air as shown in the figure and measure the C2 clutch piston stroke.

Air pressure:
400 kPa (4.1 kgfcm2, 58 psi)

C2 clutch piston stroke:
0.45 - 0.65 mm (0.0178 - 0.0255 in)

^ If not within the specification, select an appropriate retaining plate.

Retaining plate size