Clutch Drum & Input Shaft Assembly Reassembly
Clutch Drum & Input Shaft Assembly Reassembly1. Apply A/T fluid to new 2 O-rings (1) and then install O-rings to direct clutch piston.
2. Install clutch balancer No.2 (1) and direct clutch return spring (2) to direct clutch piston sub assembly.
3. Apply A/T fluid to new O-ring (1), and then install O-ring to clutch drum sub assembly.
4. Press-fit direct clutch piston into clutch drum by hands.
5. Compress clutch balancer No.2 (1) until the clutch balancer No.2 is lowered to the place 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove by using special tool and hydraulic press.
CAUTION: Be careful when applying pressure, for overpressure will cause direct clutch return spring to deform.
6. Install snap ring (1) as set snap ring end gap between snap ring stoppers (2) of clutch balancer No.2.
7. Apply A/T fluid to new O-ring (1), and then install O-ring to reverse clutch piston sub assembly.
8. Press-fit clutch drum sub assembly (1) into reverse clutch piston (2) by hands.
CAUTION: Do not twist or deviate O-rings during installation.
9. Apply A/T fluid to new O-ring (1), and then install O-ring to reverse clutch piston sub assembly.
10. Install reverse clutch return spring (2) onto reverse clutch piston sub assembly.
11. Place clutch balancer No.3 (1) onto reverse clutch piston sub assembly.
CAUTION: Do not twist or deviate O-ring during installation.
12. Compress clutch balancer No.3 (1) until the clutch balancer No.3 is lowered to the place 1 -2 mm (0.039 - 0.078 inch) from the snap ring groove by using special tool and hydraulic press, and then install snap ring.
CAUTION: Be careful when applying pressure, for overpressure will cause reverse clutch return spring to deform.
Special Tool (A): 09926-96040
13. Set end gap of snap ring (1) in piston as shown in figure.
14. Install direct clutch plates "P" and direct clutch discs "D" in the following order.
P - P - D - P - D - P - D - P - D - P - D
15. Install direct clutch flange "F".
16. Install 2 snap rings (1) by using flat end rod or the like being sure not to align snap rings end gap with cut portion of clutch drum sub assembly.
17. Measure pack clearance of direct clutch by applying compressed air (392 kPa, 4.0 kg/cm2, 57 psi) into oil hole (1) of oil pump (2) as shown in figure.
Direct clutch pack clearance 0.50 - 0.80 mm (0.020 - 0.031 inch)
NOTE: Install a selective flange (t 3.4 mm) when measuring the moving distance. (shaded area in figure.)
^ Flange moving distance A: 0.36 - 1.242 mm (0.0141 - 0.0489 inch)
Piston stroke: Flange moving distance A - 0.15 mm (0.0059 inch)
If the pack clearance is out of specification, select another flange with suitable thickness from the list below and replace it.
Available direct clutch flange thickness
Available direct clutch flange thickness:
18. Install reverse clutch flange (1).
19. Install reverse clutch reaction sleeve (1), clutch cushion plate (2), reverse clutch flange "F", reverse clutch discs "D" and reverse clutch plates "P" in the following order.
D - P - D - P - D - P - D - P - D - F
20. Install snap ring (1) by using flat end rod or the like being sure not to align snap ring end gap with cut portion of clutch drum sub assembly.
21. Measure reverse clutch piston stroke (A) and the moving distance (B) of reverse clutch flange at the both end across a diameter by applying compressed air (392 kPa, 4 kg/cm2, 57 psi) into oil hole (1) of oil pump (2) as shown in figure.
Pack Clearance 0.5 - 0.8 mm (0.020 - 0.031 inch)
NOTE: Install selective flange (t 3.3 mm) when measuring the moving distance. (shaded area in figure)
^ Piston stroke A: 1.69 - 2.81 mm (0.0665 - 0.11 inch)
Flange moving distance B: 1.20 - 1.68 mm (0.0472 - 0.0661 inch)
Pack clearance: Piston stroke A - Flange moving distance B - 0.16 mm (0.0063 inch)
If the pack clearance is out of specification, select another flange with suitable thickness from the list below and replace it.
Available reverse clutch flange thickness
Available reverse clutch flange thickness:
22. Remove snap ring (1) from clutch drum sub assembly by using flat end rod or the like.
23. Remove reverse clutch reaction sleeve (1), clutch cushion plate (2), reverse clutch flange "F", reverse clutch discs "D" and clutch plates "P" from clutch drum sub assembly.
24. Apply A/T fluid to new 2 O-rings (1) and then install O-rings to forward clutch piston.
25. Apply A/T fluid to new O-ring (1), and then install O-ring to clutch balancer No.1.
26. Install forward clutch piston (1), clutch balancer No.1 (3) and forward clutch return spring (2).
CAUTION: Do not twist or deviate O-rings during installation.
27. Compress clutch balancer No.1 (1) until the clutch balancer No.1 is lowered to the place 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove by using special tool and hydraulic press.
CAUTION: Be careful when applying pressure, for overpressure will cause forward clutch return spring to deform.
NOTE: Set special tool to the width of "a" 68 mm (2.652 inch) as shown in figure.
28. Install snap ring as set snap ring end gap between snap ring stoppers (2) of clutch balancer No.1.
29. Install forward clutch flange "F".
30. Install clutch plates "P", forward clutch flange "F" and clutch discs D in the following order.
D - P - D - P - D - P - D - F
31. Install snap ring (1) by using flat end rod or the like being sure not to align snap ring end gap with cut portion of input shaft assembly.
32. Apply A/T fluid to 3 oil seal rings (1).
33. Squeeze the ends of 3 oil seal rings (1) together, and then install oil seal rings to input shaft groove.
CAUTION: Do not spread seal excessively.
34. Check seals rotate smoothly.
35. Measure forward clutch pack clearance (A) by applying compressed air (392 kPa, 4.0 kg/cm2, 57 psi) into oil hole, (1) of input shaft as shown in figure.
Pack Clearance 0.4 - 0.7 mm (0.016 - 0.027 inch)
NOTE: Install a selective flange (t 3.4 mm) when measuring the moving distance. (shaded area in figure.)
^ Flange moving distance A: 0.12 - 1.19 mm (0.00472 - 0.0468 inch)
Pack Clearance: Flange moving distance A - 0.01 mm (0.00039 inch)
If pack clearance is out of specification, select another flange with suitable thickness from the list below and replace it.
Available forward clutch flange thickness
Available forward clutch flange thickness:
36. Install input shaft assembly (1) to clutch drum assembly.
37. Install thrust needle roller bearing (1) to clutch drum assembly.
38. Install thrust bearing race No.2 (1) and input shaft thrust bearing race (2) to forward clutch hub.
39. Install forward clutch hub (1) to clutch drum assembly.
40. Install 2 thrust needle roller bearings (1) to direct clutch hub.
41. Install direct clutch hub (1) to clutch drum assembly.
42. Install reverse clutch plates "P" and reverse clutch discs "D" to reverse clutch hub in the following order.
D - P - D - P - D - P - D - P - D
43. Install reverse clutch flange "F".
44. Install clutch cushion plate (1) to reverse clutch hub as shown in figure.
45. Install reverse clutch reaction sleeve (1) to reverse clutch hub.
46. Install reverse clutch hub sub assembly (1) including reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 4 reverse clutch discs and 3 reverse clutch plates to clutch drum assembly.
47. Install snap ring (1) on clutch drum and input shaft assembly by using flat end rod or the like.
