Forward Clutch

Forward Clutch:

DISASSEMBLY





1. REMOVE SNAP RING
Using a screwdriver, remove the snap ring.





2. REMOVE FLANGE, DISC AND PLATE
Remove the flange, 4 discs and 4 plates.
3. REMOVE PISTON RETURN SPRING.





a. Using SST on the clutch balancer, and compress the return spring with a press.
SST 09320-89010
b. Using a snap ring expander, remove the snap ring.





c. Remove the clutch balancer and piston return spring.
4. REMOVE FORWARD CLUTCH PISTON





a. Place the input shaft onto the oil pump.
b. Holding the forward clutch piston with your hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil pump to remove the forward clutch piston.

HINT: When the piston can not be removed as it is slanted, either blow the air again with the protruding side pushed or remove the piston using the needle nose plier with vinyl tape on the tip.





c. Using a screwdriver, remove the O-ring.

INSPECTION





1. INSPECT DISC, PLATE AND FLANGE
Check to see if the sliding surface of the disc, plate and flange are worn or burnt.
If necessary, replace them.

HINT:
- If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs.
- Before assembling new discs, soak them in ATF for at least 15 minutes.





2. CHECK FORWARD CLUTCH PISTON RETURN SPRING
Using a vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 21.69 mm (0.8540 inch)

REASSEMBLY





1. INSTALL FORWARD CLUTCH PISTON
a. Coat a new O-ring with ATF, and install it to the forward clutch piston.
b. Install the forward clutch piston to the input shaft.
2. INSTALL PISTON RETURN SPRING





a. Place the piston return spring and clutch balancer onto the piston.





b. Place SST on the clutch balancer, and compress the re turn spring with a press.
SST 09320-89010
c. Install the snap ring with a snap ring expander. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

NOTICE:
- Stop the press when the spring sheet is lowered to the place 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove, preventing the snap sheet from the deforming.
- Do not expand the snap ring excessively.





3. INSTALL PLATE, DISC AND FLANGE
Install the 4 plates, 4 discs and flange.
Install in order: P - Plate, D = Disc, F = Flange
P - D - P - D - P - D - P - D - F





4. INSTALL SNAP RING
Using a screwdriver, install the snap ring.





5. CHECK PACK CLEARANCE OF FORWARD CLUTCH
Using a dial indicator, measure the pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance: 1.406 - 1.806 mm (0.05535 - 0.07110 inch)
If the piston stroke is less than the limit, parts may have been assembled incorrectly, check and reassemble again.
If the clearance is non-standard, select another flange.

HINT: There are 4 different flanges in thickness.





Flange thickness: mm (inch)