Part 2
DISASSEMBLYHIGH CLUTCH AND REVERSE CLUTCH
1) Remove the snap ring, and then take out the retaining plate, drive plate and driven plate.
2) Remove the snap ring, and then take out the retaining plate, drive plate and driven plate.
3) Using the ST1 and ST2, remove the snap ring.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
4) Take out the clutch cover, spring retainer, high clutch piston and reverse clutch piston.
5) Remove the seal ring and lip seal from the high clutch piston and reverse clutch piston.
PLANETARY GEAR AND LOW CLUTCH
1) Remove the snap ring from low clutch drum.
2) Take out the front planetary carrier.
3) Take out the rear sun gear.
4) Take out the rear planetary carrier, washer and thrust needle bearing.
5) Take out the rear internal gear.
6) Remove the snap ring from low clutch drum.
7) Compress the spring retainer of the low & reverse brake, and remove the snap ring from the low clutch drum using ST1 and ST2.
ST1 498627100 SEAT
ST2 398673600 COMPRESSOR
8) Remove the one-way clutch.
9) Install the one-way clutch inner race to the low clutch drum, and then 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
Separate the 2-4 brake piston and piston retainer.
ONE-WAY CLUTCH INNER RACE
1) Remove the seal ring.
2) Remove the needle bearing using ST.
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 AND REVERSE CLUTCH
1) Install a new seal ring and lip seal to the high clutch piston and reverse clutch piston.
2) Install the high clutch piston to the reverse clutch piston.
NOTE:
Be careful not to damage the seal ring and lip seal.
3) Install the reverse clutch piston to the high clutch drum. Align the groove on reverse clutch piston with the groove on high clutch drum during installation.
4) Install the spring retainer to the high clutch piston.
5) Attach the ST to the high clutch piston.
ST 498437000 HIGH CLUTCH PISTON GUIDE
6) Install the cover to the high clutch piston while making sure not to bend the high clutch piston seal.
7) Install the snap ring by using ST1, ST2 and ST3.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 498437000 HIGH CLUTCH PISTON GUIDE
8) Measure the amount of drive plate compression and record that value.
(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 the 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 the flat board that will be placed on the retaining plate.
NOTE:
^ Use a stiff board which does not bend against load as a flat board to be put on retaining plate.
^ Use a flat board weighing less than 25.5 kg (56.2 lb).
4) Put the flat board on retaining plate.
5) Using the following formula, read the push/pull gauge, and calculate "N".
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 with a force of N using a push/pull gauge, and measure and record height "A". Measure at three or more locations spaced by equal distances and take the average value.
NOTE:
If measuring in three locations, measure every 120° C. If measuring in four locations, measure every 90° C.
9) Install the thickest driven plate to piston side, and then install the driven plate, drive plate, retaining plate to high clutch drum.
10) Install the snap ring to high clutch drum.
11) Apply compressed air intermittently to check for operation.
12) Check the piston stroke. (Non-turbo model)
1) Measure 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 recorded before. If the calculated value exceeds the service limits, replace the drive plate and select and adjust the retaining plate to be within initial standard values.
T = A + B
T: Piston stroke
A: Amount of drive plate compression
B: Clearance between retaining plate and snap ring
Initial standard:
2.0 - 2.3 mm (0.079 - 0.091 in)
Limit thickness:
2.6 mm (0.102 in)
13) Measure the clearance between the high clutch retaining plate and snap ring. (Turbo model) At this time, do not press down the retaining plate.
Initial standard:
0.8 - 1.1 mm (0.031 - 0.043 in)
Limit thickness:
1.5 mm (0.059 in)
If the clearance exceeds the service limits, replace the drive plate, then select and adjust the retaining plate so that the clearance is within default standard values.
14) Selection of the 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 retaining plate, 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 the flat board that will be placed on the retaining plate.
NOTE:
^ Use a stiff board which does not bend against load as a flat board to be put on retaining plate.
^ Use a flat board weighing less than 15.3 kg (33.7 lb).
4) Put the flat board on retaining plate.
5) Using the following formula, read the push/ pull gauge, and calculate "N".
N = 150 N (15.3 kgf, 33.7 lbf) - Z
N: Value indicated on push/pull gauge
150 N (15.3 kgf, 33.7 lbf): Load applied to the clutch plate
Z: Flat board weight
6) Press the center of retaining plate with a force of N using a push/pull gauge, and measure and record height "A". Measure at three or more locations spaced by equal distances and take the average value.
NOTE:
If measuring in three locations, measure every 120° C. If measuring in four locations, measure every 90° C.
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 Calculate with A and B dimensions recorded before. If the calculated value exceeds the service limits, replace the drive plate and select and adjust the retaining plate to be within initial standard values.
T = A + B
T: Piston stroke
A: Amount of drive plate compression
B: Clearance between retaining plate and snap ring
Initial standard:
1.1 - 1.4 mm (0.043 - 0.055 in)
Limit thickness:
1.6 mm (0.063 in)
PLANETARY GEAR AND LOW CLUTCH
1) Apply ATF to a new D-ring, and install it to the low clutch piston.
2) Install the low clutch piston to low clutch drum.
NOTE:
Be careful not to damage the D-ring.
3) Install the spring retainer to low clutch piston.
4) Attach the ST to the low clutch drum.
ST 498437100 LOW CLUTCH PISTON GUIDE
5) Using ST1, ST2 and ST3, set the cover on the piston and press against it, and attach the snap ring. At this time, be careful not to bend the cover seal.
ST1 498627100 SEAT
ST2 398673600 COMPRESSOR
ST3 498437100 LOW CLUTCH PISTON GUIDE
6) Install the dish plate, driven plate, drive plate and retaining plate, and then secure them with a snap ring.
7) Check the low clutch for operation.
1) Remove the one way clutch.
2) Set the one-way clutch inner race, and apply compressed air for checking.
8) Check the low clutch clearance.
1) Place same thickness shims on both sides to prevent plate from tilting.
2) Check the clearance between retaining plate and low clutch operation.
Initial standard:
0.7 - 1.1 mm (0.028 - 0.043 in)
Limit thickness:
1.6 mm (0.063 in)
If the clearance exceeds the service limits, replace the drive plate, then select and adjust the retaining plate so that the clearance is within default standard values.
9) Install the washer to the rear internal gear.
10) Install the rear internal gear.
11) Install the thrust needle bearing in the correct direction.
12) Install the washer by aligning the protrusion of the washer with the hole of the rear planetary carrier.
13) Install the rear planetary carrier to the low clutch drum.
14) Install the thrust needle bearing in the correct direction.
15) Install the rear sun gear in the correct direction.
16) Install the thrust needle bearing in the correct direction.
17) Install the front planetary carrier to the low clutch drum.
18) Install the snap ring to the low clutch drum.
19) Install the needle bearing, and then secure with the snap ring.
20) Install the one-way clutch and one-way clutch inner race, then secure with the snap ring.
21) Set the inner race. Make sure that the clutch locks in the clockwise direction and rotates freely in the counterclockwise direction.
2-4 BRAKE
1) Apply ATF to the new D-ring, then install to the 24 brake piston.
2) Install 2-4 brake piston to 2-4 brake piston retainer.
NOTE:
Be careful not to damage the D-ring.
ONE-WAY CLUTCH INNER RACE
1) Install the needle bearing to inner race using ST and a press.
ST 398497701 INSTALLER
2) Apply Vaseline to the groove of inner race and to the new seal ring.
3) Install two seal rings to the one-way clutch inner race.
ONE-WAY CLUTCH OUTER RACE
1) Install the needle bearing, and then secure with the snap ring.
2) Install the one-way clutch and one-way clutch inner race, then secure with the snap ring.
3) Set the inner race. Make sure that the clutch locks in the clockwise direction and rotates freely in the counterclockwise direction.
INSPECTION
HIGH CLUTCH AND REVERSE CLUTCH
Check the following items.
^ Drive plate facing for wear or damage
^ Driven plate for discoloration (burned color)
^ Snap ring wear and spring retainer deformation
^ Wear and damage of the lip seal and D-ring
^ Piston and piston check ball operation
^ Adjust the total end play.
PLANETARY GEAR AND LOW CLUTCH
Check the following items.
^ Drive plate facing for wear or damage
^ Driven plate for discoloration (burned color)
^ Snap ring wear and spring retainer deformation
^ Wear and damage of the lip seal and D-ring
^ Check the total end play and adjust it to be within
specifications.
2-4 BRAKE
Check the following items.
^ Drive plate facing for wear or damage
^ Driven plate for discoloration (burned color)
^ Snap ring wear, leaf spring setting and breakage, and spring retainer deformation
^ Wear and damage of the lip seal and D-ring
^ Check the total end play and adjust it to be within specifications.
ONE-WAY CLUTCH
^ Check that the snap ring is not damaged and the seal ring is not deformed.
^ Measure the total end play and adjust it to be within specifications.
LOW & REVERSE BRAKE
Check the following items.
^ Drive plate facing for wear or damage
^ Driven plate for discoloration (burned color)
^ Snap ring wear, leaf spring setting and breakage, and spring retainer deformation
^ Lip seal wear and damage