Part 2
DISASSEMBLYHIGH CLUTCH, REVERSE CLUTCH
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.
PLANETARY GEAR, LOW CLUTCH
1. Remove snap ring from the low clutch drum.
2. Take out front planetary carrier.
3. Take out rear sun gear.
4. Take out rear planetary carrier, washer and thrust needle bearing.
5. Take out rear internal gear.
6. Remove the snap ring from the low clutch drum.
7. Compress the spring retainer, and remove the snap ring from the low clutch drum, by using ST1 and ST2.
ST1 498627100SEAT
ST2 398673600 COMPRESSOR
8. Remove one-way clutch.
9. Install the one-way clutch inner race to the low clutch drum, and apply compressed air to remove the low clutch piston.
10. Remove the one-way clutch inner race.
11. Remove the one-way clutch after taking out the snap ring.
12. Remove the needle bearing after taking out the snap ring.
2-4BRAKE
1. Separate 2-4 brake piston and piston retainer.
2. Remove the D-ring from 2-4 brake piston.
ONE-WAY CLUTCH INNER RACK
1. Remove seal rings.
2. Using ST, remove needle bearing.
ST3 98527700PULLER ASSY
ONE-WAY CLUTCH OUTER RACK
1. Remove the one-way clutch after taking out the snap ring.
2. Remove the needle bearing after taking out the snap ring.
ASSEMBLY
HIGH CLUTCH, REVERSE CLUTCH
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. 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 GUIDE
6. Avoid folding the high clutch piston seal, when installing the cover to high clutch piston.
7. Using ST1 and ST2, install snap ring.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 498437000 HIGH CLUTCH PISTON GUIDE
8. Selection of high clutch retaining plate (Turbo model)
1. Install the thickest driven plate to piston side, and then install the driven plate, drive plate, retaining plate to high clutch drum.
2. Install snap ring to high clutch drum.
3. Apply compressed air intermittently to check for operation.
4. Measure the clearance between the retaining plate and snap ring. (High clutch) At this time, do not press down retaining plate.
Initial standard: 0.8 - 1.1 mm (0.031 - 0.043 inch)
Limit thickness: 1.5 mm (0.059 inch)
If specified tolerance limits are exceeded, select a suitable high clutch retaining plate. If it exceeds the service limit, replace the drive plate with a new one and adjust it within the specification.
High clutch retaining plate
31567AA710 4.7(0.185)
31567AA720 4.8(0.189)
31567AA730 4.9(0.193)
31567AA740 5.0(0.197)
31567AA670 5.1(0.201)
31567AA680 5.2(0.205)
31567AA690 5.3(0.209)
31567AA700 5.4(0.213)
9. Selection of high clutch retaining plate (Non-turbo model)
1. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
2. Set the micro gauge to clutch, and read its scale.
NOTE: The value, which is read in the gauge at this time, is zero point.
3. Scale and record the weight Z of a flat board which will be put on plates.
NOTE:
^ Use a stiff flat board which does not bend against load.
^ Use a flat board of its weight less than 25.5 kg (56.2 lb).
4. Put the flat board on retaining plate.
5. Using the following formula, calculate N indicated on the push/pull gauge. N = 250 N (25.5 kgf, 56.2 lb) - Z
N: Value indicated on push/pull gauge 250 N (25.5 kgf, 56.2 lb): Load applied to clutch plate
Z: Flat board weight
6. Press the center of retaining plate applying force of N with push/pull gauge, and then measure and record the height A. Make more than three measurements at even distance and take the average value.
NOTE: If three points, measure the height every 120°. If four points, measure the height every 90°.
7. Install the thickest driven plate to piston side, and then install the driven plate, drive plate, retaining plate to high clutch drum.
8. Install the snap ring to high clutch drum.
9. Apply compressed air intermittently to check for operation.
10. Measure and record the clearance B between the retaining plate and snap ring. (High clutch)
At this time, do not press down the retaining plate.
11. Piston stroke calculation
Select the retaining plate within the specification by calculating with A and B dimensions which have been recorded before. If the calculated value exceeds the usage limit, replace the drive plate with a new one and adjust it within the specification.
T = A + B
T: Piston stroke
A: Collapse amount of drive plate
B: Clearance between retaining plate and snap ring
Initial standard: 2.0 - 2.3 mm (0.079 - 0.091 inch)
Limit thickness: 2.6 mm (0.102 inch)
High clutch retaining plate
31567AA670 5.1(0.201)
31567AA680 5.2(0.205)
31567AA690 5.3(0.209)
31567AA700 5.4(0.213)
31567AA710 5.5(0.217)
31567AA720 5.6(0.220)
31567AA730 5.7(0.224)
31567AA740 5.8(0.228)
10. Selection of reverse clutch retaining plate (Turbo model)
1. Install driven plate, drive plate, retaining plate and snap ring.
2. Apply compressed air intermittently to check for operation.
3. Measure the clearance between the retaining plate and snap ring. (Reverse clutch) At this time, do not press down retaining plate.
Initial standard: 0.5 - 0.8 mm (0.020 - 0.031 inch)
Limit thickness: 1.2 mm (0.047 inch)
If specified tolerance limits are exceeded, select a suitable high clutch retaining plate.
If it exceeds the service limit, replace the drive plate with a new one and adjust it within the specification.
Reverse clutch retaining plate
31567AA910 4.0(0.157)
31567AA920 4.2(0.165)
31567AA930 4.4(0.173)
31567AA940 4.6(0.181)
31567AA950 4.8(0.189)
31567AA960 5.0(0.197)
31567AA970 5.2(0.205)
31567AA980 5.4(0.213)
1. Selection of reverse clutch retaining plate (Non-turbo model)
1. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
2. Set the micro gauge to clutch, and read its scale.
NOTE: The value, which is read in the gauge at this time, is zero point.
3. Scale and record the weight Z of a flat board which will be put on plates.
NOTE:
^ Use a stiff flat board which does not bend against load.
^ Use a flat board of its weight less than 15.3 kg (33.7 lb).
4. Put the flat board on retaining plate.
5. Using the following formula, calculate N indicated on the push/pull gauge. N = 150 N (15.3 kgf, 33.7 lb) - Z
N: Value indicated on push/pull gauge 150 N (15.3 kgf, 33.7 lb): Load applied to clutch plate Z: Flat board weight
6. Press the center of retaining plate applying force of N with push/pull gauge, and then measure and record the height A. Make more than three measurements at even distance and take the average value.
NOTE: If three points, measure the height every 120°. If four points, measure the height every 90°.
7. Install the driven plate, drive plate, retaining plate and snap ring.
8. Apply compressed air intermittently to check for operation.
9. Measure and record the clearance B between the retaining plate and snap ring. (Reverse clutch) At this time, do not press down the retaining plate.
10. Piston stroke calculation
Select the retaining plate within the specification by calculating with A and B dimensions which have been recorded before. If the calculated value exceeds the usage limit, replace the drive plate with a new one and adjust it within the specification.
T = A + B
T: Piston stroke
A: Collapse amount of drive plate
B: Clearance between retaining plate and snap ring
Initial standard: 1.1 - 1.4 mm (0.043 - 0.055 inch)
Limit thickness: 1.6 mm (0.063 inch)
Reverse clutch retaining plate
31567AA910 4.0(0.157)
31567AA920 4.2(0.165)
31567AA930 4.4(0.173)
31567AA940 4.6(0.181)
31567AA950 4.8(0.189)
31567AA960 5.0(0.197)
31567AA970 5.2(0.205)
31567AA980 5.4(0.213)