Forward Clutch
Preliminary Check
1. Measure piston stroke before disassembly.
a. Install forward clutch assembly (2) to transaxle rear cover (1).
b. Measure piston stroke while applying and releasing compressed air (400 - 800 kPa, 4 - 8 kgf/cm2, 57 -113 psi) through oil hole [A] using special tools.
Special tool
(A): 09900-20606
(B): 09900-20701
Forward clutch piston stroke
Standard: 0.84 - 1.06 mm (0.033 - 0.042 inch)
If measured piston stroke exceeds specified value, disassemble and inspect inner parts.
Disassembly
1. Remove snap ring (1).
2. Remove retaining plate "R", friction plates OF and separator plates "S" in the following order. R - F - S - F - S - F - S
3. Remove clutch drum thrust washer.
4. Using special tool and hydraulic press (2), compress forward clutch return spring subassembly and remove snap ring (1).
Special tool
(A): 09926-98330
CAUTION: Be careful when applying pressure, for overpressure will cause plate section of forward clutch return spring subassembly to deform.
5. Remove forward clutch return spring subassembly (3).
6. Install forward clutch piston subassembly (1) to transaxle rear cover (2).
7. Remove forward clutch piston subassembly (3) with O-rings installed through oil hole [A] compressed air (400 - 800 kPa, 4 - 8 kgf/cm2, 57 - 113 psi).
NOTE:
^ If piston does not pop out, it is recommended to use needle-nose pliers for removal.
^ Never reuse removed O-rings.
8. Remove clutch drum oil seal rings (3) from forward clutch drum subassembly (1).
9. Remove rear cover oil seal rings (4) from transaxle rear cover (2).
Reassembly
1. Coat new oil seal rings (3, 4) with A/T fluid.
2. Install them, to transaxle rear case (2) and forward clutch drum subassembly (1).
NOTE:
^ Do not spread ring ends excessively.
^ Make sure that opening ends of oil seal rings are not lined up so as to prevent fluid leakage.
3. Coat new O-rings with A/T fluid.
4. Install new O-rings to forward clutch piston subassembly.
5. Press forward clutch piston subassembly (1) to forward clutch drum subassembly (2) with fingers.
NOTE: Make sure that O-ring is not twisted or deviated from position during insertion of piston.
6. Place forward clutch return spring subassembly (1)
7. Install snap ring (2) using special tool and hydraulic press (3)
Special tool
(A): 09926-98330
NOTE:
^ When installing return spring, be careful so that return spring will not fall or tilt.
^ Do not align opening in snap ring with lug of forward clutch return spring subassembly at its retainer section.
CAUTION: Be careful when applying pressure, for overpressure will cause plate section of forward clutch return spring subassembly to deform.
8. Select and measure correct thickness of forward clutch retaining plate
Available forward clutch retaining plate thickness
3.4 mm (0.134 inch), 3.5 mm (0.138 inch), 3.6 mm (0.142 inch), 3.7 mm (0.146 inch), 3.8 mm (0.150 inch), 3.9 mm (0.154 inch)
9. Install separate plates "S", friction plates "F" and retaining plate "R" in the following order. S - F - S - F - S - F - R
10. Install snap ring (1)
NOTE: Make sure that flat end of retaining plate faces toward upper side. Also, make sure that opening end of ring is not aligned with groove section.
11. Apply A/T fluid to ring gear thrust roller bearing, race (1) and clutch drum thrust washer (2).
Ring gear thrust roller bearing dimension
Outside diameter: 32.5 mm (1.28 inch)
Inside diameter: 18.8 mm (0.74 inch)
Thickness: 2.7 mm (0.11 inch)
Ring gear thrust roller bearing race dimension
Outside diameter: 30.5 mm (1.20 inch)
Inside diameter: 19.0 mm (0.75 inch)
Thickness: 0.8 mm (0.03 inch)
12. Install them onto clutch drum subassembly.
13. Measure piston stroke of forward clutch piston subassembly again.
Special tool
(A): 09900-20606
(B): 09900-20701
Forward clutch piston stroke
Standard: 0.84 - 1.06 mm (0.033 - 0.042 inch)
Inspection
1. Check that sliding surfaces of friction, separator and retaining plates are not worn or burnt. If necessary, replace.
NOTE:
^ If friction plate lining is exfoliated, discolored or worn hardly, replace all friction plates.
^ Before assembling new friction plates, soak them in A/T fluid for at least two hours.
2. Measure height of forward clutch return spring.
Forward clutch return spring height
Standard: 18.8 mm (0.74 inch)
NOTE: Do not apply excessive force when measuring spring height. Perform measurement at several points.
3. Check that ball makes creaking noise when shaking forward clutch piston. (i.e., check that ball is free.)
4. Check that there is no leakage from backside of oil hole [A] by applying low pressure air.