Part 2 of 2
AT Main CaseDISASSEMBLY
HIGH 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 498627100 SEAT
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.
2-4 BRAKE
1) Separate 2-4 brake piston and piston retainer.
2) Remove the D-ring from 2-4 brake piston.
ONE-WAY CLUTCH INNER RACE
1) Remove seal rings.
2) Using ST, remove needle bearing.
ST 398527700 PULLER ASSY
ONE-WAY CLUTCH OUTER RACE
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) Install the snap ring using ST 1, 2, and 3.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 498437000 HIGH CLUTCH PISTON GUIDE
8) Install the thickest driven plate to piston side, and then install the driven plate, drive plate, retaining plate to high clutch drum.
9) Install the snap ring to high clutch drum.
10) Apply compressed air intermittently to check for operation.
11) 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 dial 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 (5 6.2 lbs.).
(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 lbs.) - Z
N: Value indicated on push/pull gauge
250 N (25.5 kgf, 56.2 lbs.): 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°.
12) Measure the clearance between the retaining plate of high clutch and snap ring. (Turbo model) At this time, do not press down the retaining plate.
If it exceeds the service limit, replace the drive plate with a new one and adjust it within the specification.
NOTE:
Do not make adjustment unless the drive plate is replaced.
13) Check the piston stroke. (Non-turbo model)
(1) 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.
(2) Piston stroke calculation
Calculate with "A" and "B" dimensions which have been recorded before, and if the value exceeds the service 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)
14) Selection of reverse clutch retaining plate
(1) Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
(2) Set the dial 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 lbs.).
(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 lbs.) - Z
N: Value indicated on push/pull gauge
150 N (15.3 kgf, 33.7 lbs.): 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.
15) Check the piston stroke.
(1) 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.
(2) Piston stroke calculation
Calculate with "A" and "B" dimensions which have been recorded before, and if the value exceeds the service 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
NOTE:
Do not make adjustment unless the drive plate is replaced.
PLANETARY GEAR, LOW CLUTCH
1) Install D-ring to low clutch piston.
2) Fit the low clutch piston to the low clutch drum.
3) Install spring retainer to low clutch piston.
4) Install ST to low clutch drum.
ST 498437100 LOW CLUTCH PISTON GUIDE
5) Set the cover on the piston with a press using ST1 and ST2, and attach the snap ring. At this time, be careful not to fold cover seal during installation. ST1 498627100 SEAT
ST2 398673600 COMPRESSOR
ST3 498437100 LOW CLUTCH PISTON GUIDE
6) Install the dish plate, driven plates, drive plates, and retaining plate, and secure with the snap ring.
7) Check the low clutch for operation.
(1) Remove one-way clutch.
(2) Set the one-way clutch inner race, and apply compressed air for checking.
8) Checking low clutch clearance.
(1) Place the same thickness of shim on both sides to prevent retaining plate from tilting.
(2) Inspect clearance between retaining plate and operation of the low clutch.
Do not make adjustment unless the drive plate is replaced.
If it exceeds the service limit, replace the drive plate with a new one and adjust it to the specification.
9) Install washer to rear internal gear.
10) Install rear internal gear.
11) Install thrust needle bearing in the correct direction.
12) Install the washer by aligning protrusion of washer and hole of rear planetary carrier.
13) Install rear planetary carrier to low clutch drum.
14) Install thrust needle bearing in the correct direction.
15) Install the rear sun gear in proper direction.
16) Install the thrust needle bearing in proper direction.
17) Install front planetary carrier to low clutch drum.
18) Install snap ring to low clutch drum.
19) Install the needle bearing, and secure with the snap ring.
20) Install the one-way clutch, and secure with the snap ring.
21) Set the inner race. Make sure that the clutch is locked in the clockwise direction and rotates in the counterclockwise direction.
2-4 BRAKE
1) Apply ATF to new D-ring, and install it to 2-4 brake piston.
2) Install 2-4 brake piston to 2-4 brake piston retainer.
ONE-WAY CLUTCH INNER RACE
1) Using a press and ST, install the needle bearing to the inner race.
ST 398497701 INSTALLER
2) Apply Vaseline to the groove of the inner race and to the seal ring.
3) Install two seal rings to one-way clutch inner race.
ONE-WAY CLUTCH OUTER RACE
1) Install the needle bearing, and secure with the snap ring.
2) Install the one-way clutch, one-way clutch inner race and plate, and secure with the snap ring.
3) Set the inner race. Make sure that the clutch is locked in the clockwise direction and rotates in the counterclockwise direction.
INSPECTION
HIGH CLUTCH AND REVERSE CLUTCH
Inspect the following items:
^ Drive plate facing for wear and damage
^ Discoloration of driven plate (Burnt color)
^ Snap ring for wear, return spring for setting and breakage, and snap ring retainer for deformation
^ Lip seal and D-ring for damage
^ Piston and drum check ball for operation
^ Adjust total end play.
PLANETARY GEAR AND LOW CLUTCH
Inspect the following items:
^ Drive plate facing for wear and damage
^ Discoloration of driven plate (Burnt color)
^ Snap ring for wear, return spring for breakage or setting, and spring retainer for deformation
^ Lip seal and D-ring for damage
^ Piston check ball for operation
^ Measure the total end play and adjust to within specifications.
2-4 BRAKE
Inspect the following items:
^ Drive plate facing for wear and damage
^ Discoloration of driven plate (Burnt color)
^ Snap ring for wear and spring retainer for deformation
^ Lip seal and D-ring for damage
^ Measure the total end play and adjust to within specifications.
ONE-WAY CLUTCH
^ Make sure the snap ring is not worn and the seal rings are not damaged.
^ Measure the total end play and adjust to within specifications.
LOW & REVERSE BRAKE
Check for the following:
^ Drive plate facing for wear or damage
^ Discoloration of driven plate (Burnt color)
^ Snap ring for wear and spring retainer for deformation