High Clutch and Reverse Clutch
A: REMOVAL1) Extract the torque converter clutch assembly.
2) Remove the input shaft.
3) Disconnect transmission harness connector from stay.
NOTE: Lift-up lever behind the connector and disconnect it from stay.
4) Disconnect inhibitor switch connector from stay.
5) Disconnect the air breather hose.
6) Remove the oil charger pipe.
7) Remove the oil cooler inlet and outlet pipes.
8) Separation of torque converter clutch case and transmission case sections
CAUTION:
^ Be careful not to damage the oil seal and bushing inside the torque converter clutch case by the oil pump cover.
^ Be careful not to lose the rubber seal.
NOTE: Separate these cases while tapping lightly on the housing.
9) Remove the oil pump housing.
10) Take out the high clutch and reverse clutch assembly.
CAUTION: Be careful not to lose thrust needle bearing.
11) Take out the high clutch hub and the thrust bearing.
B: INSTALLATION
1) Install the high clutch hub and thrust needle bearing.
Attach the thrust needle bearing to the hub with Vaseline and install the hub by correctly engaging the splines of the front planetary carrier.
2) Install the high clutch assembly.
NOTE: Correctly engage the high clutch hub and clutch splines.
3) Adjust total end play.
4) Install the oil pump housing assembly.
5) Apply proper amount of liquid gasket to the entire torque converter clutch case mating surface.
Liquid gasket: THREE BOND 1215
NOTE: Make sure that the rubber seal and seal pipe are fitted in position.
6) install the torque converter clutch case assembly to the transmission case assembly, and secure with six bolts and four nuts.
CAUTION: When installing, be careful not to damage the torque converter clutch case bushing and oil seal.
Tightening torque: 41 Nm (4.2 kgf-cm, 30.4 ft. lbs.)
7) Install air breather hose.
8) Insert inhibitor switch and transmission connector into stay.
9) Install oil cooler pipes.
10) Install the oil charger pipe with O-ring.
11) Insert the input shaft while turning lightly by hand.
CAUTION: Be careful not to damage the bushing.
Normal protrusion A: 50 - 55 mm (1.97 - 2.17 inch)
12) Install the torque converter clutch assembly.
C: DISASSEMBLY
1) Remove the snap ring, and take out the retaining plate, drive plates, driven plates.
2) Remove snap ring, and take out the retaining plate, drive plates and driven plates.
3) Using ST1 and ST2, remove snap ring.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
4) Take out clutch cover, spring retainer, high clutch piston and reverse clutch piston.
5) Remove seal rings and lip seal from high clutch piston and reverse clutch piston.
D: ASSEMBLY
1) Install seal rings and lip seal to high clutch piston and reverse clutch piston.
2) Install high clutch piston to reverse clutch piston.
3) Install reverse clutch to high clutch drum.
NOTE: Align the groove on the reverse clutch piston with the groove on the high clutch drum during installation.
4) Install spring retainer to high clutch piston.
5) Install ST to high clutch piston.
ST 498437000 HIGH CLUTCH PISTON GAUGE
6) Install cover to high clutch piston.
CAUTION: Be careful not to fold over the high clutch piston seal during installation.
7) Using ST1 and ST2, install snap ring.
NOTE: After installing snap ring, remove STs.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 498437000 HIGH CLUTCH PISTON GAUGE
8) Install driven plate, drive plate and retaining plate to high clutch drum.
NOTE: Install thicker driven plate on the piston side.
9) Install snap ring to high clutch drum.
10) Apply compressed air intermittently to check for operation.
11) Measure the clearance between the retaining plate and snap ring.
NOTE: Do not press down retaining plate during clearance measurements.
Standard value: 0.8 - 1.1 mm (0.031 - 0.043 inch)
Allowable limit: 1.5 mm (0.059 inch)
12) If specified tolerance limits are exceeded, select a suitable high clutch retaining plate.
13) Install driven plate, drive plate, retaining plate and snap ring.
14) Apply compressed air intermittently to check for operation.
15) Measure the clearance between the retaining plate and snap ring.
NOTE: Do not press down retaining plate during clearance measurements.
Standard value: 0.5 - 0.8 mm (0.020 - 0.031 inch)
Allowable limit: 1.2 mm (0.047 inch)
16) If specified tolerance limits are exceeded, select a suitable high clutch retaining plate.
E: INSPECTION
^ Drive plate facing for wear and damage
^ Snap ring for wear, return spring for setting and breakage, and snap ring retainer for deformation
^ Lip seal and lathe cut ring for damage
^ Piston and drum check ball for operation
^ Adjust total end play.