Disassembly and Reassembly

Direct Clutch Disassembly and Reassembly

Automatic Transmission Unit Disassembly

Direct Clutch Components

Disassembly

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






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






3) Using special tool and hydraulic press (1), compress direct clutch piston return spring (3) and remove retaining return spring ring (2).

NOTE:
Applying excessive pressure when compressing the piston return spring will deform the spring's plate section.

Do not apply any more pressure than is necessary.

Special Tool

(A): 09926-98310





4) Remove direct clutch piston return spring.
5) Install direct clutch cylinder to center support.

Remove direct clutch piston by blowing air into the second hole from the left as shown in figure. Also, remove direct clutch inner piston by blowing air into hole at the extreme right. And then remove O-rings from pistons.






Reassembly

Direct Clutch Inspection

Bearing and Race Installation Specification

Reassemble 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.

NOTE:
Applying excessive pressure when compressing the piston return spring will deform the spring's plate section.

Do not apply any more pressure than is necessary.

Special Tool

(A): 09926-98310









- Use care so that direct clutch piston return spring will not fall or tilt.
- 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 (1) facing the front.











- Install direct clutch assembly (1) to center support (2) and with compressed air (400 - 800 kPa, 4 - 8 kgf/cm2, 57 - 113 psi) applied to oil hole (3), measure stroke of direct clutch piston as shown in figure.
If it is not within standard range, select another plate with suitable thickness from the list below and replace it.






Direct clutch piston standard stroke
0.90 - 1.30 mm (0.035 - 0.051 in.)