Part 2

Clutch Disassembly (Continued)

Special Tools Required
^ Clutch spring compressor attachment 07LAE-PX40100 or 07HAE-PL50100
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A

1. Remove the snap ring using a screwdriver.





2. Remove the clutch end-plate (A), the clutch discs (B) (5), the clutch wave-plates (C) (4), the clutch flat plate (D) and the waved spring (E) from the 1st clutch drum (F).





3. Make a reference mark on the clutch flat-plate.
4. Remove the clutch end-plate (A), the clutch discs (B) (6), the clutch wave-plates (C) (5), the flat-plate (D), and the waved spring (E) from the 2nd clutch drum (F).





5. Make a reference mark on the flat-plate.
6. Remove the clutch end-plate (A), the clutch discs (B) (6), the clutch wave-plates (C) (5), the clutch flat plate (D), and the waved spring (E) from the 3rd clutch drum (F).





7. Make reference marks on the clutch flat-plate.
8. Remove the clutch end-plate (A), the clutch discs (B) (4), the clutch wave-plates (C) (4), and the waved spring (D) from the 4th clutch drum (E).





9. Remove the clutch end-plate (A), the clutch discs (B) (4), the clutch wave-plates (C) (4), and the waved spring (D) from the 5th clutch drum (E).





10. Install the clutch spring compressor attachment and the clutch spring compressor bolt assembly.





11. Be sure the clutch spring compressor attachment (A) is adjusted to have full contact with the spring retainer (B) on the 4th and 5th clutches.





12. Set the clutch spring compressor attachment (A) on the spring retainer (B) of the 1st, 2nd, and 3rd clutches so that it pushes on the clutch return. spring (C).





13. Check the placement of the clutch spring compressor attachment. If either end of the clutch spring compressor attachment is set over an area of the spring retainer which is unsupported by the return spring, the spring retainer may be damaged.





14. Compress the return spring until the snap ring can be removed.





15. Remove the snap ring using snap ring pliers.





16. Remove the clutch spring compressor attachment and the clutch spring compressor bolt assembly.
17. Remove the snap ring (A), the spring retainer (B), and the return spring (C).





18. Wrap a shop rag around the clutch drum (A), and apply air pressure to the fluid passage to remove the piston (B). Place a finger tip on the other passage while applying air pressure.





19. 1st, 2nd, and 3rd clutches:
Remove the clutch piston (A), remove the O-ring (B) from the piston, and remove the O-ring (C) from the clutch drum (D).





20. 4th and 5th clutches:
Remove the clutch piston (A), and remove the outer O-ring (B) and the inner O-ring (C) from the piston.





Clutch Inspection

1. Inspect the clutch pistons and the clutch piston check valves (A).





2. If the clutch piston check valve is loose or damaged, replace the clutch piston.
3. Check the spring retainer for wear and damage.
4. If the spring retainer is worn or damaged, replace it.
5. Check the oil seal (A) on the spring retainer of the 1st, 2nd, and 3rd clutches for wear, damaged, and peeling.





6. If the oil seal is worn, damaged, or peeling, replace the spring retainer.
7. Inspect the clutch discs, the clutch plates, and the clutch end plate for wear, damage, and discoloration.

Clutch Discs for All Models
Standard Thickness: 1.94 mm (0.076 in.)

Clutch Plates
Standard Thickness:
1st Clutch
Wave plates: 1.6 mm (0.063 in.)
Flat-plates: 1.6 mm (0.063 in.)
2nd Clutch
Wave-plates: 2.0 mm (0.079 in.)
Flat-plate: 2.0 mm (0.079 in.)
3rd Clutch
Wave-plates: 1.6 mm (0.063 in.)
Flat-plates: 1.6 mm (0.063 in.)
4th Clutch (wave-plates): 2.0 mm (0.079 in.)
5th Clutch (wave-plates): 2.0 mm (0.079 in.)

8. If the clutch discs are worn or damaged, replace them as a set. If the clutch discs are replaced, inspect the clearance between the clutch end-plate and the top disc.
9. If any plate is worn, damaged, or discolored, replace the damaged plate with a new plate, and inspect the other wave plates for a phase difference. If the clutch plate is replaced, inspect the clearance between the clutch end-plate and the top disc.
10. If the clutch end plate is worn, damaged, or discolored, inspect the clearance between the clutch end-plate and the top disc, then replace the clutch end plate.

Clutch Wave-plate Phase Difference Inspection

1. Place the clutch wave-plate (A) on a surface plate, and set a dial indicator (B) on the wave-plate.





2. Find the bottom (C) of a phase difference of the wave-plate, zero the dial indicator and make a reference mark on the bottom of the wave-plate.
3. Rotate the wave-plate about 60-degrees apart from the bottom while holding the wave-plate by its circumference. The dial indicator should be at the top (D) of a phase difference. Do not rotate the wave-plate while holding its surface, always rotate it with holding its circumference.
4. Read the dial indicator. The dial indicator reads the phase difference (E) of the wave-plate between bottom and top.

Standard Phase Difference:
1st Clutch: 0.15-0.25 mm (0.006-0.010 in.)
2nd Clutch: 0.1-0.2 mm (0.004-0.008 in.)
3rd Clutch: 0.1-0.2 mm (0.004-0.008 in.)
4th Clutch: 0.1-0.2 mm (0.004-0.008 in.)
5th Clutch: 0.1-0.2 mm (0.004-0.008 in.)

5. Rotate the wave-plate about 60-degrees. The dial indicator should be at the bottom of a phase difference (F and G), and zero the dial indicator.
6. Measure the phase difference at the other two tops (H and I) of the wave-plate by following steps 3 thru 5.
7. If two of the three measurements are within the standard, the wave-plate is OK. If two of the three measurements are out of the standard, replace the wave-plate.

Clutch Clearance Inspection

Special Tools Required
Clutch compressor attachment 07ZAE-PRP0100

1. Inspect the clutch piston, the discs, the plates, and the end-plate for wear and damage, and inspect the clutch wave-plate phase difference, if necessary.
2. Install the clutch piston in the clutch drum. Do not install the O-rings during inspection.





3. Install the waved spring (A) in the 1st clutch drum (B). Install the clutch flat-plate (C), then starting with the clutch disc, alternately install the clutch discs (D) (5) and the clutch wave-plates (E) (4), then install the clutch. end-plate (F) with the flat side toward the top disc.





4. Install the waved spring (A) in the 2nd clutch drum (B). Install the flat-plate (C), then starting with the clutch disc, alternately install the clutch discs (D) (6) and the wave-plates (E) (5), then install the clutch end-plate (F) with the flat side toward the top disc.





5. Install the waved spring (A) in the 3rd clutch drum (B). Install the clutch flat-plate (C), then starting with the clutch disc, alternately install the clutch discs (D) (6) and the clutch wave-plates (E) (5), then install the clutch end-plate (F) with the flat side toward the top disc.





6. Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch wave-plate, alternately install the clutch wave-plates (C) (4) and the clutch discs (D) (4), then install the clutch end-plate (E) with the flat side toward the top disc.





7. Install the waved spring (A) in the 5th clutch drum (B). Starting with the clutch wave-plate, alternately install the clutch wave-plates (C) (4) and the clutch discs (D) (4), then install the clutch end-plate (E) with the flat side toward the top disc.





8. Install the snap ring using a screwdriver.





9. Set a dial indicator (A) on the clutch end-plate (B).





10. Zero the dial indicator with the clutch end-plate lifted up to the snap ring (C).
11. Release the clutch end-plate to lower the clutch end-plate, then put the clutch compressor attachment on the clutch end-plate (A).





12. Press the clutch compressor attachment down with 147 N (15 kgf, 33 lbf) (B) using a force gauge, and read the dial indicator (C).
13. The dial indicator reads the clearance (D) between the clutch end-plate and the top disc (E). Take measurements in at least three places, and use the average as the actual clearance.

Clearance between Clutch End-Plate and Top Disc Service Limit:
1st Clutch: 1.38-1.58 mm (0.054-0.062 in.)
2nd Clutch: 1.14-1.34 mm (0.045-0.053 in.)
3rd Clutch: 1.23-1.43 mm (0.048-0.056 in.)
4th Clutch: 0.93-1.13 mm (0.037-0.044 in.)
5th Clutch: 0.93-1.13 mm (0.037-0.044 in.)

14. If the clearance (A) is out of the service limit, select a new clutch end-plate from the following table.

















15. Install a new clutch end-plate, and recheck the clearance. If the thickest clutch end-plate is installed, but the clearance is still over the service limit, replace the clutch discs and the plates.

1st, 2nd, and 3rd Clutch Reassembly

Special Tools Required
^ Clutch spring compressor attachment 07LAE-PX40100 or 07HAE-PL50100
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A

NOTE: Hold the spring compressor attachment in a vise with soft jaws. Be careful not to damage the clutch drum.

1. Soak the clutch discs thoroughly in ATF for at least 30 minutes.
2. Install a new O-ring (A) in the 1st, 2nd, and 3rd clutch pistons (B), and install a new O-ring (C) on the clutch drums (D).





3. Install the clutch piston (A) in the clutch drum (B). Apply pressure and rotate to ensure proper seating. Lubricate the piston O-ring with ATF before installing. Do not pinch the O-ring by installing the piston with too much force.





4. Set the return spring (A) and the spring retainer (B), and position the snap ring (C) on the spring retainer.





5. Install the clutch spring compressor attachment and the clutch spring compressor bolt assembly.





6. Set the clutch spring compressor attachment (A) on the spring retainer (B) so that it compresses the clutch return spring (C).

NOTE: Coat the circumference of the spring retainer and areas where the spring retainer contacts the clutch piston with ATF before installation.





7. Compress the return spring carefully until the snap ring can be installed. Check that the spring retainer (A) is properly installed on the clutch hub (B). If improperly installed, change the position of the spring compressor attachment and the spring retainer.

NOTE: Insert the spring retainer so it can be adjusted (center of tolerance) to prevent damaging the spring retainer oil seal.





8. Install the snap ring using snap ring pliers.





9. Remove the clutch spring compressor attachments and the clutch spring compressor bolt assembly.
10. Make sure the oil seal of the spring retainer (A) is properly installed on the clutch piston (B). If the oil seal was damaged or cracked, replace the spring retainer.





11. Install the wave spring (A) in the 1st clutch drum (B). Install the clutch flat-plate (C) (1), then starting with the clutch disc, alternately install the clutch discs (D) (5) and the wave-plates (E) (4). Install the clutch end-plate (F) with the flat side toward the top disc.





12. Install the wave spring (A) in the 2nd clutch drum (B). Install the clutch flat-plate (C) (1), then starting with the clutch disc, alternately install the clutch discs (D) (6) and the wave-plates (E) (5). Install the clutch end-plate (F) with the flat side toward the top disc.





13. Install the wave spring (A) in the 3rd clutch drum (B). Install the clutch flat-plate (C) (1), then starting with the clutch disc, alternately install the clutch discs (D) (6) and the wave-plates (E) (5). Install the clutch end-plate (F) with the flat side toward the top disc.





14. Install the snap ring using a screwdriver to secure the clutch end-plate.





15. Check that the clutch piston moves by applying air pressure into fluid passage.

4th and 5th Clutch Reassembly

Special Tools Required
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A
^ Clutch spring compressor attachment 07LAE-PX40100 or 07HAE-PL50100

1. Soak the clutch discs thoroughly in ATF for at least 30 minutes.
2. Install new O-rings (A) on the clutch piston (B). Do not twist the O-rings.





3. Install the clutch piston (A) in the clutch drum (B) while applying pressure and rotating to ensure proper seating. Do not pinch the O-ring.





4. Set the return spring (A) and spring retainer (B), and position the snap ring (C) on the spring retainer.





5. Install the clutch spring compressor attachments and the clutch spring compressor bolt assembly.





6. Be sure the clutch spring compressor attachment (A) is adjusted to have full contact with the spring retainer (B).





7. Check the placement of the clutch spring compressor attachment. If either end of the clutch spring compressor attachment is set over an area of the spring retainer that is unsupported by the return spring, the retainer may be damaged.





8. Compress the return spring until the snap ring can be installed.





9. Install the snap ring using snap ring pliers.





10. Remove the clutch spring compressor attachments and the clutch spring compressor bolt assembly.
11. Install the wave spring (A) in the 4th clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (4) and the clutch discs (D) (4). Install the clutch end-plate (E) with the flat side toward the top disc.





12. Install the wave spring (A) in the 5th clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (4) and the clutch discs (D) (4). Install the clutch end-plate (E) with the flat side toward the top disc.





13. Install the snap ring using a screwdriver to secure the clutch end-plate.





14. Check that the clutch piston moves by applying air pressure into fluid passage.