Forward and Direct Clutch Disassembly and Reassembly
Forward and Direct Clutch Disassembly and ReassemblyReference: Automatic Transaxle Unit Disassembly
Reference: Automatic Transaxle Unit Assembly
Reference: Forward and Direct Clutch Components
Reference: Forward and Direct Clutch Preliminary Check
Disassembly
1. Remove snap ring (1) using flat end rod or the like.
2. Remove retaining plate "R", friction plates "F" and separator plates S in the following order.
R -> F -> S -> F -> S -> F -> S -> F -> S
NOTE: Measure thickness of removed retaining plate and record for reference of piston stroke confirmation.
3. Remove snap ring (1) using flat end rod or the like.
4. Remove retaining plate, friction plates and separator plates.
NOTE: Measure thickness of removed retaining plate and record for reference of piston stroke confirmation.
5. Using special tool and hydraulic press, compress direct clutch piston return spring and remove snap ring (1).
Special Tool
(A): 09926-95420
(B): 09940-51710
CAUTION: Be careful when applying pressure, for overpressure will cause plate section of direct clutch piston return spring to deform.
6. Remove direct clutch piston return spring (2).
7. For removing forward clutch piston and direct clutch piston, install forward and direct clutch assembly (1) to transaxle rear cover (2).
8. Remove direct clutch piston (3) with O-rings by applying compressed air (400 - 800 kPa, 4 - 8 kg/cm2, 57 - 113 psi) through oil hole (4).
NOTE: If piston does not pop out, it is recommended to use needle-nose pliers for removal.
9. Remove forward clutch piston (1) with O-rings by applying compressed air (400 - 800 kPa, 4 - 8 kg/cm2, 57 - 133 psi) from through oil hole (2).
NOTE: If piston does not pop out, it is recommended to use needle-nose pliers for removal.
10. Remove oil seal ring (1) from input shaft (2).
NOTE: Never reuse removed oil seal ring.
Reassembly
Reference: Forward and Direct Clutch Inspection
1. Apply A/T fluid to new oil seal ring and install new oil seal ring (1) to input shaft (2).
2. Apply A/T fluid to new O-rings and install new O-rings to forward clutch piston.
3. Press forward clutch piston to input shaft.
NOTE: Do not twist or deviate O-rings during installation.
4. Apply A/T fluid to new O-rings and install O-rings to direct clutch piston.
5. Press direct clutch piston to input shaft.
NOTE: Do not twist or deviate O-rings during installation.
6. Install direct clutch piston return spring (2).
7. Using special tool and hydraulic press, compress direct clutch piston return spring (2) until spring seat is pushed down to 1 - 2 mm (0.039 - 0.078 inch) lower than snap ring groove and install snap ring (1).
Special Tool
(A): 09926-95420
(B): 09940-51710
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 direct clutch piston return spring at its retainer section.
CAUTION: Be careful when applying pressure, for overpressure will cause plate section of direct clutch piston return spring to deform.
8. Install separator plates S, friction plates F and retaining plate R in the following order.
S -> F -> S -> F -> S -> F -> S -> F -> R
9. Install snap ring (1).
NOTE: Make sure that opening end of ring is not aligned with groove section of input shaft.
10. Install separator plates S, friction plates F and retaining plate R in the following order.
S -> F -> S -> F -> S -> F -> S -> F -> R
NOTE: Make sure that flat end of retaining plate face toward piston side.
11. Install snap ring (1).
NOTE: Make sure that opening end of ring is not aligned with groove section of input shaft.
12. Measure forward clutch piston stroke again, using special tools.
If measured piston stroke exceeds specified value, replace forward clutch retaining plate with new one so that piston stroke is within standard value.
Special Tool
(A): 09900-20607
(B): 09900-20701
Forward clutch piston stroke
Standard: 1.52 - 1.89 mm (0.059 - 0.074 inch)
Available forward clutch retaining plate thickness 3.6 mm (0.141 inch), 3.8 mm (0.150 inch), 4.0 mm (0.158 inch)
13. Measure direct clutch piston stroke again, using special tools.
If measured piston stroke exceeds specified value, replace direct clutch retaining plate with new one so that piston stroke is within standard value.
Special Tool
(A): 09900-20607
(B): 09900-20701
Direct clutch piston stroke
Standard: 1.52 - 1.89 mm (0.059 - 0.074 inch)
Available direct clutch retaining plate thickness 3.6 mm (0.141 inch), 3.8 mm (0.150 inch), 4.0 mm (0.158 inch)
