Third Clutch Assembly

THIRD CLUTCH ASSEMBLY

DISASSEMBLY





1. Mount 3rd clutch assembly to soft jawed vise as shown in image and then set special tool to it.

Special Tool (C): 09920-36010/J-29351

2. Compress 3rd clutch retaining ring by sliding compressing ring of special tool. Then push out inside clutch plate by inserting a screwdriver through holes in housing at two places evenly so that retaining ring is removed from its groove slightly.

CAUTION: Do not apply excessive force to screwdriver. It may cause damage to clutch plate.

3. Pull off compressing ring of special tool and then remove special tool carefully.





4. Using 2 small screwdrivers, push out 3rd clutch hub (one-way clutch assembly) and remove retaining ring from its groove in housing completely.









5. Remove clutch hub and take out clutch plates, thrust bearing and thrust washer from housing. Be sure to keep clutch plates in the order as they were installed.
6. Disassembly 3rd clutch hub into sprag race, sprag and planetary input gear.





7. Compress return spring seat with special tool and press and remove retaining ring. Then take out spring seat, spring and 3rd clutch piston.

NOTE:
^ Care must be taken not to press spring seat too much to prevent it from deformation.
^ Do not open retaining ring excessively.

Special Tool
(B): 09920-76010/J-8059
(D): 09927-66020/J-23075

INSPECTION AND INSTALLATION





1. Check 3rd clutch piston for operation by shaking it and listening to check ball in it move.
2. Check piston and seal and replace if necessary.
Seal should be installed with its lip faced toward pressure side as shown.





3. When replacing seal located inside of 3rd clutch housing (input shaft), install it with its lip faced down.
4. Air-check 3 oil passages in 3rd clutch housing (input shaft).





5. Apply transmission fluid to both seals of 3rd clutch piston and in clutch housing and insert piston into housing carefully.
6. Place 12 return springs onto piston. Burned or deformed springs must be replaced, if any.





7. Place spring seat and using the same special tool and press as in disassembly, compress return spring and fit retaining ring.

CAUTION:
^ While compressing spring seat, care should be taken lest it catch in retaining ring groove.
^ Do not press spring seat excessively or it may be deformed.
^ Do not open retaining ring too much when installing it in groove. Deformed retaining ring should be replaced with a new one.

Special Tool
(B): 09920-76010/J-8059
(D): 09927-66020/J-23075





8. Wash and air-dry one-way clutch (sprag) parts thoroughly and check that they are free of wear or damage. Then coat them with transmission fluid and install them properly.
Sprag should be installed with flared shoulder around sprag cage faced toward input sun gear at assembled position in 3rd clutch hub.





9. After installation, check sprag race for proper rotation. Hold sun gear with left hand and try to turn sprag race with right hand in both directions. It should rotate freely in arrow direction but lock in the other way.

NOTE: Rotation check of one-way clutch must be performed without fail.





10. Check clutch plates for excessive wear, burn and flaking. After confirming that they are in good condition, install them to input sun gear (3rd clutch hub) in the order of steel plate, lined plate and spring cushion plate at the end.
Cushion plate should be installed in such way that its inner circumference contacts steal plate and outer circumference doesn't.

NOTE: When installing clutch plates, be sure to lubricate them by transmission fluid sufficiently.





11. With 3rd clutch housing (input shaft) held horizontally with soft jawed vise, insert thrust washer and thrust bearing and then install 3rd clutch hub assembly (one way clutch assembly) into it.

NOTE: Thrust washer used here is thicker than the one used in front of planetary gear carrier although their diameters are identical. Make sure to use the right one.





12. Use special tool as follows to install 3rd clutch hub and sprag assemblies into input shaft (3rd clutch housing).
1. Put compressor pins of special tool on retaining ring.
2. Compress retaining ring inward by sliding compressing ring of special tool.
3. Push special tool and sprag race forward together so that retaining ring is held a little by 3rd clutch housing.
4. Slide off compressing ring of special tool to open its compressor pins and remove it from retaining ring (sprag race) calmly.

Special Tool (E): 09920-36010/J-29351





13. Insert sprag race by hand and fit retaining ring into ring groove in housing.

NOTE: Don't push input sun gear when installing 3rd clutch hub and sprag assemblies. Only gear may move inward and cause clutch plates to fall off.


INSTALLING 3RD CLUTCH ASSEMBLY INTO 2ND CLUTCH ASSEMBLY





With tangs of 2nd clutch plate aligned, install 3rd clutch assembly to 2nd clutch assembly.