Disassembly and Assembly
Direct ClutchDirect Clutch:
DISASSEMBLY
1. Carry out the preinspection before disassembly. Operation and Pre-Inspection
2. Disassemble in the order indicated in the illustration, noting the following notes:
Snap Ring (8)
CAUTION: Depress the spring retainer only enough to remove the snap ring. Overpressing will damage the retainer component edges.
1. Compress the spring by using the Special Service Tools (SSTs), then remove the snap ring by using snap-ring pliers.
2. Remove the spring retainer and spring.
Clutch Piston (11)
1. Install the direct clutch onto the drum support along with the seal rings.
2. Remove the piston by applying compressed air to the oil passage. Air pressure of 392 kPa (57 psi) max.
ASSEMBLY
1. Measure the facing thickness in three places, and determine the average of the three readings. Standard thickness is 1.6 mm (0.063 inch). Minimum thickness is 1.4 mm (0.055 inch).
2. If it is less than the minimum, replace the drive plates.
3. Measure the spring specifications.
4. If not correct. replace the return spring.
5. Verify that there is no air leakage when applying compressed air through the oil hole opposite the return spring.
6. Verify that there is airflow when applying compressed air through the oil hole on the return spring side. Air pressure of 392 kPa (57 psi) maximum.
7. If not as specified, replace the clutch piston.
8. Apply ATF to a new O-ring and install it into the direct clutch drum.
9. Apply ATF to a new seal ring and install it onto the piston.
10. Apply ATF to the inner surface of the direct clutch drum.
11. Apply even pressure to the perimeter of the clutch piston, and install it into the direct clutch drum by turning it evenly and gradually.
12. Verify that the piston can be turned by hand. If it cannot, then remove it and check for damage to the seal ring.
CAUTION: Depress the spring retainer only enough to install the snap ring. Overpressing will damage the retainer component edges.
13. Install the springs and spring retainer while compressing them by using the SST.
14. While holding the spring retainer down by using the SST, install the snap ring into the spring retainer stopper.
15. Soak new drive plates in ATF for at least two hours.
16. Apply ATF to the driven plates immediately before installation.
17. Install the drive and driven plates into the direct clutch drum in the following order. Driven-Drive-Driven -Drive
18. Install the snap ring.
19. Apply ATF to the outer race, and install the outer race so that the toothless area is in line with the lubrication hole in the direct clutch drum.
20. Apply ATF to the one-way clutch, and install it into the outer race. Verify that the spring cage of the one-way clutch faces toward the direct clutch drum.
21. Apply ATF to the side plate, and install the side plate so that the toothless area is in line with the lubrication hole in the direct clutch drum.
22. Install the snap ring.
23. Apply petroleum jelly to the bearing, and install it onto the direct clutch drum. Bearing outer diameter is 70.0 mm (2.756 inch).
24. Measure the clearance between the side plate and the snap ring by using a feeler gauge. If not within specification, adjust the clearance by installing the correct side plate. Maximum clearance is 0.2 mm (0.008 inch).
25. Insert the fourth gear clutch hub on the top of the direct clutch and verify that the fourth gear clutch hub rotates smoothly when turned clockwise and locks when turned counterclockwise. If it does not, then the one-way clutch is installed upside down.
CAUTION: Applying compressed air to the assembled clutch pack for longer than 3 seconds at a time will damage the seal.
26. Install the direct clutch onto the drum support along with the seal rings. Apply compressed air to the oil passage and check the clutch operation. Air pressure of 392 kPa (67 psi) maximum.