Part 2
Clutch Inspection1. Check the oil seal (A) on the spring retainer of the 1st, 2nd, and 3rd clutches for wear, damage, and peeling.
2. If the oil seal is worn, damaged, or peeling, replace the spring retainer.
3. Inspect the 4th, and 5th clutch pistons and the clutch piston check valves (A).
4. If the clutch piston check valve is loose or damaged, replace the clutch piston.
5. Check the spring retainer for wear and damage.
6. If the spring retainer is worn or damaged, replace it.
7. Inspect the clutch discs, the clutch plates, and the clutch end-plate for wear, damage, and discoloration.
Standard Thickness
Clutch Discs: 1.94 mm (0.076 in.)
Clutch Plates:
1st clutch (waved-plates): 1.6 mm (0.063 in.)
2nd clutch:
Waved-plates: 2.0 mm (0.079 in.)
Flat-plate: 2.0 mm (0.079 in.)
3rd clutch:
Waved-plates: 1.6 mm (0.063 in.)
Flat-plates: 1.6 mm (0.063 in.)
4th clutch (waved-plates): 2.0 mm (0.079 in.)
5th clutch (waved-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 waved-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 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). 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, discs, plates, and endplate for wear and damage, and inspect the clutch wave-plate phase difference, if necessary.
2. 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 discs (D) (5) and the wave-plates (E) (4). Install the clutch endplate (F) with the flat side down on the top disc.
3. 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 discs (D) (6) and the wave-plates (E) (5). Install the clutch end-plate (F) with the flat side down on the top disc.
4. 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 discs (D) (6) and the wave-plates (E) (5). Install the clutch end-plate (F) with the flat side down on the top disc.
5. Install the clutch pistons in the 4th and 5th clutch drums. Do not install the O-rings during inspection.
6. 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 discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
7. 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 discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
8. Install the snap ring with a screwdriver to secure the clutch end-plate.
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 it, then put the special tool on the end-plate (A).
12. Press the clutch compressor attachment down with 150-160 N (15-16 kgf, 33-35 lbf) (B) using a force gauge, and read the dial indicator (C). 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.
Clutch End-Plate-to-Top Disc Clearance
Service Limit:
1st Clutch: 1.38-1.58 mm (0.054-0.062 in.)
2nd Clutch: 1.18-1.38 mm (0.046-0.054 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.)
13. If the clearance is out of the service limit, select a new clutch end-plate from the following tables.
14. 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.
Clutch Reassembly
Special Tools Required
^ Snap ring pliers 07LGC-0010100
^ Clutch spring compressor attachment 07HAE-PL50101
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A
NOTE: Hold the spring compressor attachment in a vice with soft jaws. Be careful to damage the clutch drum.
1. Soak the clutch discs thoroughly in ATF for a minimum of 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 a new O-rings (A) on the 4th and 5th clutch piston (B).
4. 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 to much force.
5. Install the return spring (A) and spring retainer (B), and position the snap ring (C) on the spring retainer.
6. Install the special tools.
7. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 4th and 5th clutches.
8. Make sure both ends of the clutch spring compressor attachment are set over an area of the spring retainer that is supported by the return spring, otherwise the retainer may be damaged.
9. Set the special tool (A) on the spring retainer (B) of the 1st, 2nd, and 3rd clutches so the special tool works on the clutch return spring (C).
10. If either end of the special tool is not set over the clutch return spring end (A), the retainer may be damaged.
11. Compress the return spring until the snap ring can be installed.
12. Install the snap ring with the snap ring pliers.
13. Remove the special tools.
14. Make sure the oil seal of the spring retainer (A) is properly installed on the clutch piston (B). If the outer circumference of the oil seal was damaged or cracked, replace the spring retainer.
15. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.
16. 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 discs (D) (5) and the wave-plates (E) (4). Install the clutch endplate (F) with the flat side down on the top disc.
17. 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 discs (D) (6) and the wave-plates (E) (5). Install the clutch end-plate (F) with the flat side down on the top disc.
18. 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 discs (D) (6) and the wave-plates (E) (5). Install the clutch end-plate (F) with the flat side down on the top disc.
19. 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 discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
20. 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 discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
21. Install the snap ring with a screwdriver to secure the clutch end-plate.
22. Check that the clutch piston moves by applying air pressure into the fluid passage.