Clutch

Clutch









Removal

WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.

NOTICE: After installation of the transaxle be sure to perform the Clutch Adaptive Learning procedure or transaxle damage can occur. For additional information, refer to Transmission Adaptive Learning Transmission Adaptive Learning.

1. Remove the transaxle from the vehicle. For additional information, refer to Transaxle Transaxle.

2. Install the special tools.





3. Stand the transaxle on its back.

4. Remove the clutch motors. For additional information, refer to Clutch Motor - No. 1 Clutch Motor - No. 1 and Clutch Motor - No. 2 Clutch Motor - No. 2.

5. Remove and discard the clutch hub snap ring.





6. NOTE: Index mark the clutch hub and clutch for installation.

Remove the clutch hub.





7. Install the special tools.





8. Using the special tools, turn the center bolt of the special tool with a maximum of 5 Nm (44 lb-in) of torque to push the clutch down to release the pressure from the hollow input shaft snap ring.





9. Remove and discard the hollow input shaft snap ring.





10. NOTE: Make sure the lifting legs are installed on the clutch studs marked with the stamped arrows as shown.

NOTE: Make sure the lifting leg with the angle is in the location shown.

Install the special tools.





11. Install the special tools.





12. Turn the center bolt of the special tool with approximately 5 Nm (44 lb-in) of torque until the clutch is free of the input shaft.





13. Using the special tools, remove the clutch as an assembly from the transaxle.





Installation

1. If installing a new clutch go to step 19.

2. NOTE: Make sure the special tool washer is also installed.

Install the special tool in a vise.





3. Place the clutch on the special tool and align one clutch stud with the slotted hole on the special tool.





4. Install the special tool loosely on the clutch.





5. Install the special tool on the clutch making sure the legs are inserted in the slots.





6. Turn the special tool clockwise to the stops and hold.





7. NOTICE: Failure to rotate the self-adjuster to the stops before compressing the clutch, causes damage to the clutch.

Tighten the special tool until the 3 clutch 1 locks can be locked in place by hand.





8. Install the special tool loosely on the clutch.





9. Using the special tool, move the clutch self-adjuster counterclockwise to the stop and hold.





10. NOTE: An audible click can be heard when the clutch locks lock.

Using the special tool, compress the clutch to the stops on the clutch. The locks on clutch 2 lock at this time.





11. Remove the special tools.





12. NOTE: The minimum number of engaged clutch locks is 6. Make sure the 6 locked clutch fingers align with the clutch studs as shown. If not, reset the clutch 2 locks as necessary.

Visually check the locks to make sure they have locked. 3 locks shown, 12 total.





13. If installing a used clutch, verify the clutch is not worn or damaged. Perform the next 2 steps to check for clutch wear.

14. Check clutch 1 for wear by measuring the distance between the adjuster ring 1 long hole and lever 1 spring. Replace the clutch assembly if the measurement is 26 mm (1.023 in) or less.





15. Check clutch 2 for wear by measuring the distance between adjuster ring 2 and the cover. Replace the clutch assembly if the measurement is 15 mm (0.59 in) or less.





16. Apply a small amount of transmission fluid on the input shaft bearing surface.





17. Apply a small amount of DPS6 Grease on both input shaft splines.





18. Verify the Z-washers are installed correctly.





19. NOTICE: Verify the clutch locks are locked prior to installation or the transaxle may not operate correctly and damage can occur. If the clutch locks are not locked go to step 2 within this procedure.

Using the special tools, install the clutch in the transaxle.





20. Remove all the special tools.





21. Install the special tools onto the transaxle case.





22. NOTICE: Do not overtighten the special tool or damage can occur.

Using the special tools, push the clutch down with approximately 5 Nm (44 lb-in) of torque until seated on the input shaft bearing and the snap ring groove is visible.





23. NOTE: Make sure the hollow input shaft snap ring is fully seated.

Install the new hollow input shaft snap ring.





24. NOTE: Align the index marks on the clutch hub and clutch.

Install the clutch hub.





25. Install the new clutch hub snap ring in the position shown.





26. NOTICE: Do not turn the special tool more than 12 turns or damage to the clutch actuator engagement lever can occur.

Using the special tool, release the clutch 1 locks and then the clutch 2 locks by slowly turning the special tool counterclockwise. An audible click will be heard when the clutch locks are released.





27. Install the clutch motors. For additional information, refer to Clutch Motor - No. 1 Clutch Motor - No. 1 and Clutch Motor - No. 2 Clutch Motor - No. 2.

28. NOTICE: After installation of the transaxle be sure to perform the Clutch Adaptive Learning procedure or transaxle damage can occur. For additional information, refer to Transmission Adaptive Learning Transmission Adaptive Learning.

Install the transaxle in the vehicle. For additional information, refer to Transaxle Transaxle.