Direct Clutch

DISASSEMBLY





1. CHECK PACK CLEARANCE OF DIRECT CLUTCH
a. Install the direct clutch and needle roller bearing on the transaxle rear cover.
b. Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance: 0.605 - 0.825 mm (0.02382 - 0.03248 inch)
If the pack clearance is non-standard, inspect the discs, plates and flange.





2. REMOVE SNAP RING
Using a screwdriver, remove the snap ring from the direct clutch.





3. REMOVE FLANGE, DISC AND PLATE
Remove the flange, 3 discs and 3 plates from the direct clutch drum.
4. REMOVE PISTON RETURN SPRING





a. Place SST on the clutch balancer and compress the springs with a press.
SST 09387-00020
b. Using a snap ring expander, remove the snap ring from the direct clutch drum.

NOTICE:
^ Stop the press when the spring sheet is lowered to the place of 1 - 2 mm (0.039 - 0.078 inch) away from the snap ring groove.
^ This prevents the spring sheet from being deformed.
^ Do not expand the snap ring excessively.





c. Remove the clutch balancer from the direct clutch drum.





d. Remove the piston return spring from the direct clutch drum.





5. REMOVE DIRECT CLUTCH PISTON
a. Install the direct clutch drum on the transaxle rear cover.
b. Holding the direct clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle rear cover to remove the direct clutch piston.

INSPECTION





1. INSPECT DISC AND FLANGE
Check 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 peeled off or discolored, or if a part of the printed mark is defaced, replace all the discs.
^ Before assembling new discs, soak them in ATF for at least 15 minutes.





2. CHECK DIRECT CLUTCH RETURN SPRING
Using vernier calipers, measure the free length of the spring with the spring seat.
Standard free length: 22.58 mm (0.8890 inch)

REASSEMBLY





1. INSTALL DIRECT CLUTCH PISTON
Coat the direct clutch piston with ATF, and install it to the direct clutch drum.

NOTICE: Be careful not to damage the lip seal of the direct clutch piston.





2. INSTALL PISTON RETURN SPRING
Install the piston return spring to the direct clutch drum.
3. INSTALL CLUTCH BALANCER





a. Install the clutch balancer to the direct clutch drum.

NOTICE: Be careful not to damage the lip seal of the direct clutch balancer.





b. Place SST on the clutch balancer and compress the piston return spring with a press.
SST 09387-00020
c. Using a snap ring expander, install the snap ring to the direct clutch drum.

NOTICE:
^ Be sure the end gap of the snap ring is not aligned with the clutch balancer claw.
^ Stop the press when the spring sheet is lowered to the place of 1 - 2 mm (0.039 - 0.078 inch) away from the snap ring groove.
^ This prevents the spring sheet from being deformed.
^ Do not expand the snap ring excessively.

4. INSTALL PLATE, DISC AND FLANGE





a. Install the 3 plates, 3 discs and flange.
Install in order: P = Plate, D = Disc, F = Flange
P - D - P - D - P - D - F





b. Using a screwdriver, install the snap ring.
c. Check that the end gap of the snap ring is not aligned with one of the cutouts.





5. CHECK PACK CLEARANCE OF DIRECT CLUTCH
a. Install the direct clutch on the transaxle rear cover.
b. Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance: 0.605 - 0.825 mm (0.02382 - 0.03248 inch)
If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble them again.
If the stroke is non-standard, select another flange.

HINT: There are 6 flanges in different thickness.





Flange Thickness: mm (in.)





6. CHECK DISK ROTATE
Check that the disc rotates when rotating the disk after inserting the rear planetary sun gear.

NOTICE: Do not place the rear planetary sun gear in a vise.