Forward Clutch

FORWARD CLUTCH

Components





Forward Clutch Disassembly






1. CHECK PISTON STROKE OF FORWARD CLUTCH
Using a dial indicator (long type pick or Special Service Tool (SST)), measure the forward clutch piston stroke applying and releasing the compressed air (392-785 kPa, 4-8 kgf/cm2, 57-114 psi), as shown.
SST 09350-32014 (09351-32190)

Piston stroke: 1.79 - 2.21 mm (0.0705 - 0.0870 inch)





If the piston stroke is greater than the maximum, inspect each component.





2. REMOVE SNAP RING FROM CLUTCH DRUM





3. REMOVE FLANGE, DISCS AND PLATES
4. REMOVE RETURN SPRING





a. Place SST on the spring retainer and compress the springs with a shop press.
SST 09350-32014 (09351 -32070)
b. Using snap ring pliers, remove the snap ring.





c. Remove the return spring.

5. REMOVE CLUTCH PISTON





a. Apply compressed air into the oil passage to remove the piston.
If the piston does not come out, use needle-nose pliers to remove it.





b. Remove the two O-rings from the piston.





6. IF NECESSARY, REMOVE OIL SEAL RINGS
Remove the three oil seal rings from the shaft.


Forward Clutch Inspection



1. INSPECT CLUTCH PISTON
a. Check that the check ball is free by shaking the piston.
b. Check that the valve does not leak by applying low-pressure compressed air.





2. INSPECT DISCS, PLATES AND FLANGE
Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them.

HINT:
- If the lining of the disc is peeling off or discolored, or even a part of the printed numbers are defaced, replace all discs.
- Before assembling new disc, soak them in Automatic Transmission Fluid (ATF) for at least fifteen minutes.


Forward Clutch Assembly



1. INSTALL OIL SEAL RINGS
Install the three oil seal rings to the shaft.

NOTICE: Do not spread the ring ends more than necessary.

HINT: After installing the oil seal rings, check that they move smoothly.

2. INSTALL CLUTCH PISTON TO CLUTCH DRUM





a. Install the two new O-rings to the piston.





b. Coat the O-ring with Automatic Transmission Fluid (ATF).
c. Press the piston into the drum with the cup side up, being careful not to damage the O-rings.





3. INSTALL PISTON RETURN SPRINGS
a. Place the return spring and snap ring onto the piston.
b. Place SST on the spring retainer, and compress the springs with a shop press.
SST 09350-32014 (09351 -32070)
c. Install the snap ring with snap ring pliers.
Be sure the end gap of the snap ring is not aligned with the spring retainer claw.





4. INSTALL PLATES, DISCS AND FLANGE
a. Install the plates and discs.
Install in order:
P = Plate D = Disc
P-D-P-D-P-D-P-D-P-D

b. Install the flange with the flat end facing downward.





5. INSTALL SNAP RING
Check that the end gap of snap ring is not aligned with one of the cutouts.








6. RECHECK PISTON STROKE OF FORWARD CLUTCH
Using a dial indicator (long type pick or SST), measure the forward clutch piston stroke applying and releasing the compressed air (392-785 kPa, 4-8 kgf/cm2, 57-114 psi), as shown.
SST 09350-32014 (09351-32190)

Piston stroke: 1.79 - 2.21 mm (0.0705 - 0.0870 inch)

If the piston stroke is nonstandard, select another flange.

HINT: There are two different thicknesses for the flange.

Flange thickness:
2.30 mm (0.0906 inch)
2.70 mm (1.0630 inch)