Reverse Clutch

Preliminary Inspection





1. Remove sun gear input flange (1) with thrust washer (2) installed by removing retainer ring (3).





2. Remove input shaft (1) with input shaft rear thrust roller bearing race (3), input shaft rear thrust roller bearing (2), input shaft front thrust roller bearing (4) and input shaft front thrust roller bearing race (5).





3. Remove snap ring (2) of reverse clutch drum with bearing (1).
4. Install sun gear input flange (thrust washer installed) with retainer ring.
5. Mount reverse clutch drum with bearing to oil pump body (1).





6. Measure piston stroke with compressed air (400 - 800 kPa, 4 - 8 kgf/cm2, 57 - 113 psi) through oil hole section [A], using special tools.
Special tool
(A): 09900-20606
(B): 09900-20701
Reverse clutch piston stroke
Standard: 1.54 - 1.86 mm (0.061 - 0.073 inch)

NOTE:
^ To prevent air leakage from oil hole section [A] during piston stroke measurement with air nodule gun, it is recommended to plug oil hole section around air nozzle gun with a clean cloth or the like because piston stroke cannot be measured otherwise.
^ If it is difficult to obtain correct specified value, it is recommended to align plate (Thickness: approximately 3 mm) with shape around oil hole section.

Disassembly
1. Remove reverse clutch drum with bearing (1) from oil pump body.





2. Remove sun gear input flange (2) with thrust washer (3) installed by removing retainer ring (4).
3. Remove friction plates "F", separator plates "S" and cushion plate "C" in the following order.
F - S - F - S - C





4. Remove reverse clutch return spring by removing snap ring (1), using special tool and hydraulic press (2).
Special tool
(A): 09926-96010

NOTE: To prevent deformation of spring seat, it is recommended to compress spring seat until claw section of snap ring is free.

5. Mount reverse clutch drum with bearing (2) to oil pump body (3).
6. Remove reverse clutch piston (1) by blowing compressed air (400 - 800 kPa, 4 - 8 kgf/cm2, 57 - 113 psi) through oil hole section [A].





7. Remove two O-rings from piston.

NOTE: Never reuse removed O-rings.

Reassembly
1. Apply A/T fluid to new O-rings.
2. Install them to reverse clutch piston (1).





3. Press reverse clutch piston (1) into reverse clutch drum with bearing (2) with cup side up.

NOTE: Do not twist or deviate O-rings during installation.

4. Place reverse clutch return spring onto reverse clutch piston.





5. Install snap ring (1), using special tool and hydraulic press (2).
Special tool
(A): 09926-96010

NOTE: To prevent spring seat deformation, be sure to keep clearance of 1 - 2 mm between return spring seat and snap ring.

6. Install cushion plate "C", separator plates "S" and friction plates "F" in the following order.
C - S - F - S - F

NOTE: Make sure that flat end section of plate faces toward piston side.





7. Install sun gear input flange (1) with retainer ring (2).
8. Measure piston stroke.
9. Remove reverse clutch from oil pump body.
10. Remove sun gear input flange by removing retainer ring.





11. Install snap ring (2) to reverse clutch drum with bearing (1).
12. Apply A/T fluid to input shaft rear thrust roller bearing (1).
13. Install input shaft rear thrust roller bearing (1) to input shaft (3).
Input shaft rear thrust roller bearing dimension
Outside diameter: 31.2 mm (1.23 inch)
Inside diameter: 18.6 mm (0.73 inch)
Thickness: 2.7 mm (0.11 inch)
14. Apply A/T fluid to input shaft rear thrust roller bearing race (2).





15. Install input shaft rear thrust roller bearing race (2) to input shaft (3).
Input shaft rear thrust roller bearing race dimension
Outside diameter: 33.4 mm (1.31 inch)
Inside diameter: 21.5 mm (0.85 inch)
Thickness: 2.0 mm (0.08 inch)
16. Install input shaft to reverse clutch drum.
17. Install sun gear input flange (1) with retainer ring (3).
18. Apply A/T fluid to thrust washer





19. Install thrust washer (2) to reverse clutch assembly
20. Apply A/T fluid to input shaft front thrust roller bearing and race.





21. Install thrust needle roller bearing and race (1) to reverse clutch assembly (2).
Input shaft front thrust roller bearing dimension
Outside diameter: 33.1 mm (1.30 inch)
Inside diameter: 18.6 mm (0.73 inch)
Thickness: 3.4 mm (0.13 inch)
Input shaft front thrust roller bearing race dimension
Outside diameter: 34.4 mm (1.35 inch)
Inside diameter: 21.5 mm (0.85 inch)
Thickness: 0.8 mm (0.03 inch)

Inspection





1. Check that sliding surfaces of friction, separator and cushion 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 reverse clutch return spring.
Reverse clutch return spring height
Standard: 18.7 mm (0.74 inch)

NOTE: Do not apply excessive force when measuring spring height. Perform measurement at several points.

3. Make sure that ball (1) makes creaking noise when shaking the reverse clutch piston. (i.e., check that ball is free.)





4. Check that there is no leakage by applying low-pressure air onto ball.





5. Check that outer surface of reverse clutch with bearing is not worn or burnt. If necessary, replace.