Part 2

Clutch Inspection





1. Inspect the 3rd and 4th clutch pistons and clutch piston check valves (A).
2. If the clutch piston check valve is loose or damaged, replace the clutch piston.
3. Check the spring retainer for wear and damage.





4. Check the oil seal (A) on the spring retainer of the 1st and 2nd clutches for wear, damage, and peeling.
5. If the oil seal is worn, damaged, or peeling, replace the spring retainer.
6. Inspect the clutch discs, clutch plates, and clutch end plate for wear, damage, and discoloration.
Standard Thickness
Clutch Discs: 1.94 mm (0.076 inch)
Clutch Plates:
1st clutch plates: 1.6 mm (0.063 inch)
2nd clutch plates: 2.0 mm (0.079 inch)
3rd and 4th clutch plates: 2.0 mm (0.079 inch)
7. If the clutch discs are worn or damaged, replace them as a set. If the clutch discs are replaced, inspect the clutch end-plate-to-top-disc clearance.
8. If any plate is worn, damaged, or discolored, replace the damaged plate with the new plate, and inspect the other waved-plates for a phase difference. If the clutch plate is replaced, inspect the clutch end-plate-to-top-disc clearance.
9. If the clutch end plate is worn, damaged, or discolored, inspect the clutch end-plate-to-top-disc clearance, then replace the clutch end plate.

Clutch Waved-plate Phase Difference Inspection





1. Place the clutch waved-plate (A) on a surface plate, and set a dial indicator (B) on the waved-plate.
2. Find the bottom (D) of a phase difference of the waved-plate, zero the dial indicator and make a reference mark on the bottom of the waved-plate.
3. Rotate the 1st and 2nd clutch waved-plate about 60 degrees by holding it by its circumference, and rotate the 3rd and 4th clutch waved-plate about 72 degrees or 54-degrees apart from the bottom. The dial indicator should be at a top (E) of a phase difference. Do not rotate the waved-plate by holding its surface, always rotate it holding its circumference.
4. Read the dial indicator. The dial indicator reads the phase difference (C) of the waved-plate between bottom and top.
Standard: 0.07 - 0.20 mm (0.003 - 0.008 inch)
Minimum: 0.05 mm (0.002 inch)
5. Rotate the 1st and 2nd clutch waved-plate about 60 degrees from the top position, and rotate the 3rd and 4th clutch waved-plate 54-degrees or 72 degrees apart from the top. The dial indicator should be at the bottom of a phase difference (F and H). Zero the dial indicator.
6. Measure the phase difference at the other two tops (G and I) of the waved-plate by following steps 3 thru 5.
7. If the two values of the three measurements are within the standard, the waved-plate is OK. If the two values of the three measurements are out of the standard, replace the waved-plate.

Clutch Clearance Inspection

Special Tools Required
Clutch compressor attachment 07ZAE-PRP0100

1. Inspect the clutch piston, discs, plates, and end plate for wear and damage, and inspect clutch waved-plate phase difference, if necessary.





2. Install the clutch piston in the clutch drum. Do not install the O-rings during inspection.





3. Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (5) and discs (D) (5), then install the clutch end-plate (E) with the flat side toward the disc.





4. 2003-2004 models 2nd clutch: Install the waved spring (A) in the 2nd clutch drum (B). Install the clutch flat-plate (C), clutch disc (D), and clutch flat-plate (E). Starting with the clutch disc, alternately install the clutch discs (F) (4) and clutch waved-plates (G) (3), then install the clutch end plate (H) with the flat side toward the disc.





5. 2005 model 2nd clutch: Install the waved spring (A) in the 2nd clutch drum (B). Install the 4.0 mm-thick plate (C) with the shear droop side (D) toward the inside of the drum, clutch disc (E), and 2.0 mm-thick flat-plate (F), then starting with the disc, alternately install the discs (G) (4) and waved-plates (H) (3), then install the clutch-end-plate (I) with the flat side toward the disc.





6. 2003-2004 models 3rd clutch: Install the waved spring (A) in the 3rd clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (3) and discs (D) (3), then install the clutch end plate (E) with the flat side toward the disc.





7. 2003-2004 models 4th clutch: Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (3) and discs (D) (3), then install the clutch end plate (E) with the flat side toward the disc.





8. 2005 model 3rd clutch: Install the waved spring (A) in the 3rd clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (4) and discs (D) (4), then install the clutch end plate (E) with the flat side toward the disc.





9. 2005 model 4th clutch: Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (4) and discs (D) (4), then install the clutch end plate (E) with the flat side toward the disc.





10. Install the snap ring with a screwdriver.





11. Set a dial indicator (A) on the clutch end plate (B).
12. Zero the dial indicator with the clutch end plate lifted up to the snap ring (C).





13. Release the clutch end plate to lower the clutch end plate, then put the special tool on the end plate (A).
14. Press the special tool down with 150 - 160 N (15 - 16 kgf, 33 - 35 lbs.) using a force gauge, and read the dial indicator (B). The dial indicator reads the clearance (C) between the clutch end plate and top disc (D). 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: 1.28 - 1.48 mm (0.050 - 0.058 inch)
2nd Clutch:
2003-2004 models: 0.85 - 1.05 mm (0.033 - 0.041 inch)
2005 model: 0.88 - 1.08 mm (0.035 - 0.043 inch)
3rd Clutch:
2003-2004 models: 0.73 - 0.93 mm (0.029 - 0.037 inch)
2005 model: 0.93 - 1.13 mm (0.037 - 0.044 inch)
4th Clutch:
2003-2004 models: 0.73 - 0.93 mm (0.029 - 0.037 inch)
2005 model: 0.93 - 1.13 mm (0.037 - 0.044 inch)





15. If the clearance is out of the service limit, select a new clutch end plate from the following table.
16. Install the new clutch end plate, then recheck the clearance.

NOTE: If the thickest clutch end plate is installed, but the clearance is still over the service limit, replace the clutch discs and plates.

Clutch Reassembly

Special Tools Required
^ Clutch spring compressor attachment 07LAE-PX40100 or 07HAE-PL50101
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A

1. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.





2. Install the new O-rings (A) on the 3rd and 4th clutch pistons (B).





3. Install the new O-ring (A) in the 1st and 2nd clutch pistons (B), and install the new O-ring (C) on the clutch drums (D).





4. Install the clutch piston (A) in the clutch drum (B). Apply pressure and rotate it to ensure proper seating. Lubricate the piston O-ring with ATF before installing. Do not pinch the O-ring by installing the piston with too much force.





5. Install the return spring (A) and spring retainer (B), and position the snap ring (C) on the 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 3rd and 4th clutches.





8. Set the special tool (A) on the spring retainer (B) of the 1st and 2nd clutches in such a way that the special tool works on the clutch return spring (C).





9. If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.





10. Compress the return spring.





11. Install the snap ring with snap ring pliers.
12. Remove the special tools.





13. Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (5) and discs (D) (5), then install the clutch end plate (E) with the flat side toward the disc.





14. 2003-2004 models 2nd clutch: Install the waved spring (A) in the 2nd clutch drum (B). Install the clutch flat-plate (C), clutch disc (D), and clutch flat-plate (E). Starting with the clutch disc, alternately install the clutch discs (F) (4) and clutch waved-plates (G) (3), then install the clutch end-plate (H) with the flat side toward the disc.





15. 2005 model 2nd clutch: Install the waved spring (A) in the 2nd clutch drum (B). Install the 4.0 mm-thick plate (C) with the shear droop side (D) toward the inside of the drum, clutch disc (E), and 2.0 mm-thick flat-plate (F), then starting with the clutch disc, alternately install the clutch discs (G) (4) and clutch waved-plates (H) (3), then install the clutch end-plate (I) with the flat side toward the disc.





16. 2003-2004 models 3rd clutch: Install the waved spring (A) in the 3rd clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (3) and discs (D) (3), then install the clutch end-plate (E) with the flat side toward the disc.





17. 2003-2004 models 4th clutch: Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (3) and discs (D) (3), then install the clutch end-plate (E) with the flat side toward the disc.





18. 2005 model 3rd clutch: Install the waved spring (A) in the 3rd clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (4) and discs (D) (4), then install the clutch end-plate (E) with the flat side toward the disc.





19. 2005 model 4th clutch: Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (4) and discs (D) (4), then install the clutch end-plate (E) with the flat side toward the disc.





20. Install the snap ring with a screwdriver.
21. Check that the clutch piston moves by applying air pressure into fluid passage.