8. Overdrive Clutch and Coast Clutch Disassembly and Reassembly

Overdrive Clutch and Coast Clutch Disassembly and Reassembly
Disassembly





1. Remove snap ring (1).
2. Remove retaining plates "R", friction plates "F" and separator plates "S" in the following order.
R -> F -> S -> F -> S -> F -> R

NOTE: Measure thickness of retaining plate and record for reference of piston stroke confirmation.

3. Remove snap ring (1).





4. Remove retaining plates "R", friction plates "F" and separator plate "S" in the following order.
R - > F -> S -> F -> R

NOTE: Measure thickness of removed retaining plate and record for reference of piston stroke confirmation.

5. 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.





6. Remove overdrive clutch return spring.
7. For removing coast clutch piston (1), install forward clutch assembly.
8. Remove coast clutch piston with O-rings using compressed air (400 - 800 kPa, 4 - 8 kgf/cm2, 57 - 113 psi) through oil hole (2).





9. Remove O-rings from coast clutch piston.

NOTE: Never reuse O-rings after removal.

10. Remove coast clutch piston (1) with O-rings using compressed air (400 - 800 kPa, 4 - 8 kgf/cm2, 57 - 113 psi) through oil hole (2).





11. 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 (1) to overdrive clutch piston (2) by pushing with fingers.





4. Press overdrive clutch and coast clutch piston to overdrive clutch drum (3).

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 retaining plate.
Available coast clutch retaining plate thickness 3.6 mm (0.142 inch), 3.8 mm (0.150 inch), 4.0 mm (0.157 inch)
7. Install separate plate "S", friction plates "F" and retaining plates "R" of coast clutch in the following order.
R -> F -> S -> F -> R

NOTE: Be sure to confirm that flat section of retaining plate faces toward piston side and also that of separate plate faces toward upper side.





8. Install snap ring (1).

NOTE: Make sure that opening end of ring is not aligned with groove section of drum.

9. Select and measure correct thickness of overdrive clutch retaining plate.
Available overdrive clutch retaining plate thickness 3.6 mm (0.142 inch), 3.8 mm (0.150 inch), 4.0 mm (0.157 inch)
10. Install separate plates "S", friction plates "F" and retaining plates "R" of overdrive clutch in the following order.
R -> F -> S -> F -> S -> F -> R

NOTE: Be sure to confirm that flat section of retaining plate selected in Step 9 faces toward piston side and also that of retaining plate faces toward upper side.





11. Install snap ring (1).

NOTE: Make sure that opening end of ring is not aligned with groove section of drum.

12. Install forward clutch assembly and overdrive and coast clutch assembly to transaxle rear cover.





13. Measure overdrive clutch piston stroke again, using special tools.
Special Tool
(A): 09900-20606
(B): 09900-20701
Overdrive clutch piston stroke
Standard: 1.04 - 1.36 mm (0.041 - 0.054 inch)





14. Measure coast clutch piston stroke again, using special tools.
Special Tool
(A): 09900-20606
(B): 09900-20701
Coast clutch piston stroke
Standard: 2.68 - 3.02 mm (0.106 - 0.119 inch)