Direct Clutch

DISASSEMBLY





1. Install direct clutch assembly (1) to center support (2) and with 4 - 8 kg/cm2 air pressure applied to second fluid hole from the left, measure stroke of direct clutch piston as shown in figure.
If it is not within standard range, use 3.55 mm, 3.75 mm or 4.0 mm (0.140 inch, 0.147 inch or 0.157 inch) clutch backing plate to adjust it to standard stroke.
Standard direct clutch piston stroke
1.06 - 2.14 mm (0.042-0.084 inch) (G16 and J20 engines)
0.91 - 1.99 mm (0.036 - 0.078 inch) (H25 engine)





2. Remove direct clutch assembly from center support and then remove retaining ring.





3. Remove clutch backing plate (1) and then remove clutch disc (3) and clutch plate (2).





4. Using special tool and hydraulic press (1), compress direct clutch piston return spring (3) and remove retaining return spring ring (2).
Special tool (A): 09926-98310

CAUTION: Be careful when applying pressure, for overpressure will cause plate section of piston return spring to deform.





5. Remove direct clutch piston return spring.
6. Install direct clutch cylinder to center support.
Remove direct clutch piston by blowing air into the second hole from the left as shown in the figure. Also, remove direct clutch inner piston by blowing air into hole at the extreme right. And then remove O-rings from pistons.

INSPECTION
Direct Clutch Piston Return Spring





^ Measure free length.
Standard free length of direct clutch piston return spring 15.13 mm (0.595 inch)

Direct Clutch Piston





^ Shake piston to check that ball is not stuck.
^ Apply air pressure and check that there is no leakage.

ASSEMBLY
Assemble each component by reversing disassembly procedure and noting the following points.








^ Always use new O-ring and apply A/T fluid before installation.
^ Do not align opening in retaining ring (2) with lug of direct clutch piston return spring at retainer.
Special tool (A): 09926-98310





^ Use care so that direct clutch piston return spring will not fall or tilt.

CAUTION: Be careful when applying pressure, for overpressure will cause plate section of piston return spring to deform.

^ Do not match opening (1) in retaining back plate ring with cutout (2) in direct clutch cylinder.








^ Install clutch backing plate with its grooved side facing the front.