Part 4

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.

ASSEMBLY

1. Install D-rings and oil seals on forward clutch piston and overrun clutch piston,
- Take care with direction of oil seal.
- Apply ATF to both parts.

2. Install overrun clutch piston assembly on forward clutch piston while turning it slowly.
- Apply ATF to inner surface of forward clutch piston.

3. Install forward clutch piston assembly on forward clutch drum while turning it slowly.
- Apply ATF to inner surface of drum.

4. Align notch in forward clutch piston with groove in forward clutch drum.

5. Install return spring on piston.
6. Install spring retainer on return springs.

7. 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.

8. Install drive plates, driven plates, retaining plate and dish plate for overrun clutch.
9. Install snap ring for overrun clutch.

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

Specified clearance:
Standard: 1.0 - 1.4 Nm (0.039 - 0.055 inch)
Allowable limit: 2.0 Nm (0.079 inch)

Overrun clutch retaining plate: Refer to image.

11. Install drive plates, driven plates, retaining plate and dish plate for forward clutch.
Take care with the order and direction of plates.
12. Install snap ring for forward clutch.

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

Specified clearance:
Standard: 0.45 - 0.85 Nm (0.0177 - 0.0335 inch)
Allowable limit: 1.85 Nm (0.0728 inch)

Forward clutch retaining plate: Refer to image.

14. Check operation of forward clutch.

15. Check operation of overrun clutch.

LOW & REVERSE BRAKE

DISASSEMBLY

1. Check operation of low & reverse brake.
a. Apply compressed air to oil hole of transmission case.
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. Stand transmission case.
3. Remove snap ring.
4. Remove drive plates, driven plates, retaining plate from transmission case.

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

6. Remove spring retainer and return springs.

- Do not remove return springs from spring retainer.

7. Apply compressed air to oil hole of transmission case while holding piston.
8. Remove piston from transmission case by turning it.

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

INSPECTION

Low & 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.

Low & Reverse Brake Drive Plate

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

Thickness of drive plate:
Standard value: 2.0 Nm (0.079 inch)
Wear limit: 1.8 Nm (0.071 inch)

- If not within wear limit, replace.

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. Stand transmission case.
3. Install piston assembly on transmission case while turning it slowly.
- Apply ATF to inner surface of transmission case.

4. Install return springs and spring retainer on piston.

5. Install snap ring while compressing return springs.
- Set Tool directly above return springs.

6. Install drive plates, driven plates, retaining plates and dished plates.
- Do not align the projections on the two dished plates.
- Make sure to put the plates in the correct order and direction.

7. Install snap ring.

8. Measure clearance between retaining plate and snap ring. If not within allowable limit, select proper retaining plate (front side).

Specified clearance:
Standard: 1.4 - 1.8 Nm (0.055 - 0.071 inch)
Allowable limit: 2.8 Nm (0.110 inch)

Retaining plate: Refer to image.