Overdrive Clutch/Coast Clutch
Preliminary Check1. Measure piston stroke. Install forward clutch assembly and overdrive/coast clutch assembly (2) to transmission rear cover (1).
2. Measure overdrive clutch piston stroke while applying and releasing compressed air (400 - 800 kPa, 4 - 8 kgf/cm2, 57 - 113 psi) through oil hole (A) by using special tools. If piston stroke exceeds specified value, disassemble and inspect inner parts.
Special tool
(A): 09900-20606
(B): 09900-20701
Specified piston stroke
For 1.6 liter model: 0.76 - 1.04 mm (0.030 - 0.040 inch)
For 1.8 liter model: 1.05 - 1.35 mm (0.041 - 0.053 inch)
3. Measure coast clutch piston stroke while applying and releasing compressed air (400 - 800 kPa, 4 - 8 kgf/cm2, 57 - 113 psi) through oil hole (A) by using special tools. If piston stroke exceeds specified value, disassemble and inspect inner parts.
Special tool
(A): 09900-20606
(B): 09900-20701
Specified piston stroke 2.68 - 3.02 mm (0.106 - 0.119 inch)
Disassembly
1. Remove flanges, discs and plate of overdrive clutch by removing snap ring (6) in the following order.
For 1.6 liter model:
(1) Flange --> (2) Disc --> (3) Plate --> (4) Disc --> (5) Flange
For 1.8 liter model:
(1) Flange --> (2) Disc --> (3) Plate --> (4) Disc --> (5) Plate --> (6) Disc --> (7) Flange
NOTE: Measure thickness of removed flange (1)and record for reference of piston stroke confirmation.
2. Remove flanges, discs and plate of coast clutch by removing snap ring (6) in the following order.
(1) Flange --> (2) Disc --> (3) Plate --> (4) Disc --> (5) Flange
NOTE: Measure thickness of removed flange (1)and record for reference of piston stroke confirmation.
3. Using special tool and hydraulic press (2), compress overdrive clutch return spring and remove snap ring (1).
Special tool (A): 09926-98310
CAUTION: Be careful when applying pressure, for overpressure will cause plate section of overdrive clutch return spring to deform.
4. Remove overdrive clutch return spring.
5. For removing coast clutch piston (1), install forward clutch assembly.
6. Remove coast clutch piston with O-rings using compressed air (400 - 800 kPa, 4 - 8 kgf/cm2, 57 - 113 psi) through oil hole (A).
7. Remove O-rings from coast clutch piston.
NOTE: Never reuse O-rings after removal.
8. Remove overdrive clutch piston (1) with O-rings using compressed air (400 - 800 kPa, 4 - 8 kgf/cm2, 57 - 113 psi) through oil hole (A).
9. Remove O-rings from overdrive clutch piston.
NOTE: Never reuse O-rings after removal.
Reassembly
1. Apply A/T fluid to new O-rings.
2. Install new O-rings to pistons.
3. Set coast clutch piston to overdrive clutch piston by pushing with fingers.
4. Press overdrive clutch and coast clutch piston to overdrive clutch drum.
NOTE: Make sure that O-rings are not twisted or deviated from position during insertion of piston.
5. Using special tool and hydraulic press (2), compress overdrive clutch return spring and install snap ring (1).
Special tool (A): 09926-98310
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 overdrive clutch return spring at its retainer section.
CAUTION: Be careful when applying pressure, for overpressure will cause plate section of spring to deform.
6. Select and measure correct thickness of coast clutch flange (flange (5) in Step 7)).
Available clutch flange size (thickness)
3.6 mm (0.142 inch)
3.8 mm (0.150 inch)
4.0 mm (0.157 inch)
7. Install flanges, discs and plate of coast clutch in the following order.
(1) Flange --> (2) Disc --> (3) Plate --> (4) Disc --> (5) Flange
NOTE: Be sure to confirm that flat section of flange (5) selected in Step 6 faces toward piston side and also that flange (1) faces toward upper side.
8. Install snap ring (6).
NOTE: Check to make sure that opening end of ring is not aligned with groove section of drum.
9. Select and measure correct thickness of overdrive clutch flange (flange (5) for 1.6 liter model or (7) for 1.8 liter model in Step 10)).
Available clutch flange size (thickness)
3.6 mm (0.142 inch)
3.8 mm (0.150 inch)
4.0 mm (0.157 inch)
10. Install flanges, discs and plate of overdrive clutch in the following order.
For 1.6 liter model:
(1) Flange --> (2) Disc --> (3) Plate --> (4) Disc --> (5) Flange
For 1.8 liter model:
(1) Flange --> (2) Disc --> (3) Plate --> (4) Disc --> (5) Plate --> (6) Disc --> (7) Flange
NOTE: Be sure to confirm that flat section of flange (5) for 1.6 liter model or (7) for 1.8 liter model selected in Step 9 faces toward piston side and also that flange (1) faces toward upper side.
11. Install snap ring (6).
NOTE: Check to make sure that opening end of ring is not aligned with groove section of drum.
12. Install forward clutch assembly and overdrive direct multiple D clutch assembly to transmission rear cover.
13. Measure overdrive clutch piston stroke again, using special tools.
Special tool
(A): 09900-20606
(B): 09900-20701
Specified piston stroke
For 1.6 liter model: 0.75 - 1.05 mm (0.030 - 0.041 inch)
For 1.8 liter model: 1.05 - 1.35 mm (0.041 - 0.053 inch)
14. Measure coast clutch piston stroke again, using special tools.
Special tool
(A): 09900-20606
(B): 09900-20701
Specified piston stroke: 2.68 - 3.02 mm (0.106 - 0.119 inch)
Inspection
1. Check that sliding surfaces of discs, plates and flanges are not worn or burnt. If necessary, replace.
NOTE:
^ If disc lining is exfoliated or discolored, or part of printed numbers ((A) section) is defaced, replace all discs.
^ Before assembling new discs, soak them in A/T fluid for at least two hours.
2. Measure height of overdrive clutch return spring.
Specified value of overdrive clutch return spring height 18.9 mm (0.74 inch)
NOTE: Do not apply excessive force when measuring spring height. Perform measurement at several points.
3. Check to make sure that ball makes creaking noise when shaking piston clockwise and counterclockwise. (i.e., check that ball (1) is free.)