Part 3

ASSEMBLY



1. Install D-ring and oil seal on piston.
- Take care with the direction of the oil seal.
- Apply ATF to both parts.




2. Install piston assembly by turning it slowly.
- Apply ATF to inner surface of drum.




3. Install return springs and spring retainer on piston.




4. Set Tool on spring retainer and install snap ring while compressing return springs.
- Set Tool directly above return springs.




5. Install drive plates, driven plates, retaining plate and dish plates.
- Do not align the projections of any two dish plates.
- Take care with the order and direction of plates.




6. Install snap ring.




7. Measure clearance between retaining plate and snap ring. If not within allowable limit, select proper retaining plate.

Specified clearance:
Standard: 0.5 - 0.8 Nm (0.020 - 0.031 inch)
Allowable limit: 1.2 Nm (0.047 inch)

Retaining plate: Refer to image.




8. Check operation of reverse clutch.


HIGH CLUTCH





DISASSEMBLY



1. Check operation of high clutch.
a. Apply compressed air to oil hole of input shaft.
- Stop up a hole on opposite side of input shaft.

b. Check to see that retaining plate moves to snap ring.
c. If retaining plate does not contact snap ring:
- D-ring might be damaged.
- Oil seal might be damaged.
- Fluid might be leaking past piston check ball.




2. Remove seal rings from input shaft.




3. Remove snap ring.
4. Remove drive plates, driven plates and retaining plate.




5. Set Tool on spring retainer and remove snap ring from high clutch drum while compressing return springs.
- Set Tool directly above springs.
- Do not expand snap ring excessively.

6. Remove spring retainer and return springs.



- Do not remove return spring from spring retainer.




7. Remove piston from high clutch drum by turning it.




8. Remove D-ring and oil seal from piston.


INSPECTION

Reverse Clutch Snap Ring, Spring Retainer And Return Springs
- Check for deformation, fatigue or damage.
- Replace if necessary.
- When replacing spring retainer and return springs, replace them as a set.

High Clutch Drive Plates



- Check facing for burns, cracks or damage.
- Measure thickness of facing.

Thickness of drive plate:
Standard value: 1.6 Nm (0.063 inch)
Wear limit: 1.4 Nm (0.055 inch)

- If not within wear limit, replace.

High Clutch Piston



- Make sure check balls are not fixed.
- Apply compressed air to check ball oil hole opposite the return spring. Make sure there is no air leakage.
- Apply compressed air to oil hole on return spring side to make sure air leaks past ball.

Seal Ring Clearance



- Install new seal rings onto input shaft.
- Measure clearance between seal ring and ring groove.

Standard clearance: 0.08 - 0.23 Nm (0.0031 - 0.0091 inch)
Allowable limit: 0.23 Nm (0.0091 inch)

- If not within wear limit, replace input shaft assembly.


ASSEMBLY



1. Install D-ring and oil seal on piston.
- Take care with the direction of the oil seal.
- Apply ATF to both parts.




2. Install piston assembly by turning it slowly.
- Apply ATF to inner surface of drum.




3. Install return springs and spring retainer on piston.




4. Set Tool on spring retainer and install snap ring while compressing return springs.
- Set Tool directly above return springs.




- Do not align snap ring gap with spring retainer stopper.




5. Install drive plates, driven plates and retaining plate.
Take care with the order and direction of plates.
6. Install snap ring.




7. Measure clearance between retaining plate and snap ring. If not within allowable limit, select proper retaining plate.

Specified clearance:
Standard: 1.4 - 1.8 Nm (0.055 - 0.071 inch)
Allowable limit: 2.6 Nm (0.102 inch)

Retaining plate: Refer to image.




8. Check operation of high clutch.




9. Install seal rings to input shaft.
- Apply petroleum jelly to seal rings.




- Roll paper around seal rings to prevent seal rings from spreading.


FORWARD CLUTCH AND OVERRUN CLUTCH





DISASSEMBLY



1. Check operation of forward clutch and overrun clutch.
a. Install bearing retainer on forward clutch drum.
b. Apply compressed air to oil hole of forward clutch drum.
c. Check to see that retaining plate moves to snap ring.




d. If retaining plate does not contact snap ring:
- D-ring might be damaged.
- Oil seal might be damaged.
- Fluid might be leaking past piston check ball.




2. Remove snap ring for forward clutch.
3. Remove drive plates, driven plates, retaining plate and dish plate for forward clutch.




4. Remove snap ring for overrun clutch.
5. Remove drive plates, driven plates, retaining plate and dish plate for overrun clutch.




6. Set Tool on spring retainer and remove snap ring from forward clutch drum while compressing return springs.
- Set Tool directly above return springs.
- Do not expand snap ring excessively.

7. Remove spring retainer and return springs.




8. Remove forward clutch piston with overrun clutch piston from forward clutch drum by turning it.




9. Remove overrun clutch piston from forward clutch piston by turning it.




10. Remove D-rings and oil seals from forward clutch piston and overrun clutch piston.


INSPECTION

Snap Rings And Spring Retainer
- Check for deformation, fatigue or damage.

Forward Clutch And Overrun Clutch Return Springs



- Check for deformation or damage.
- Measure free length and outer diameter.




Inspection standard: Refer to image.

- Replace if deformed or fatigued.

Forward Clutch And Overrun Clutch Drive Plates



- Check facing for burns, cracks or damage.
- Measure thickness of facing.

Thickness of drive plate:
Forward clutch
Standard value: 1.8 Nm (0.071 inch)
Wear limit: 1.6 Nm (0.063 inch)
Overrun clutch
Standard value: 1.6 Nm (0.063 inch)
Wear limit: 1.4 Nm (0.055 inch)

- If not within wear limit, replace.

Forward Clutch And Overrun Clutch Dish Plates



- Check for deformation or damage.
- Measure thickness of dish plate.

Thickness of dish plate "t":
Forward clutch: 2.5 Nm (0.098 inch)
Overrun clutch: 2.15 Nm (0.0846 inch)

- If deformed or fatigued, replace.

Forward Clutch Drum



- Make sure check balls are not fixed.
- Apply compressed air to check ball oil hole from outside of forward clutch drum. Make sure air leaks past ball.
- Apply compressed air to oil hole from inside of forward clutch drum. Make sure there is no air leakage.

Overrun Clutch Piston



- Make sure check balls are not fixed.
- Apply compressed air to check ball oil hole opposite the return spring. Make sure there is no air leakage.
- Apply compressed air to oil hole on return spring side. Make sure air leaks past ball.