Part 2
Shafts and Clutches ContinuedClutch 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
2003-2004 models
1st clutch (waved-plates): 1.6 mm (0.063 inch)
2nd clutch: Waved-plates: 2.0 mm (0.079 inch)
Flat-plate: 2.0 mm (0.079 inch)
3rd clutch (waved-plates): 2.3 mm (0.091 inch)
4th clutch (waved-plates): 2.3 mm (0.091 inch)
2005-2006 models
1st clutch (waved-plates): 1.6 mm (0.063 inch)
2nd clutch: Waved-plates: 2.0 mm (0.079 inch)
2.0 mm-thick flat-plate: 2.0 mm (0.079 inch)
4.0 mm-thick plate: 4.0 mm (0.157 inch)
3rd clutch (waved-plates): 2.0 mm (0.079 inch)
4th clutch (waved-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 clutch waved-plate about 60 degrees (except 2003-2004 models 3rd and 4th) or 72 or 54 degrees (2003-2004 models 3rd and 4th) by holding its circumference. The dial indicator should be at top (E) of a phase difference.
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 clutch waved-plate about 60 degrees (except 2003-2004 models 3rd and 4th) or 72 or 54° (2003-2004 models 3rd and 4th) from the top position. The dial indicator should be at bottom (F) of a phase difference. Zero the dial indicator.
6. Measure the phase difference between other two bottoms (F, H) and tops (G, I) of the clutch waved plate by following steps 3 through 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: 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. 2005-2006 models: 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: 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: 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. 2005-2006 models: 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. 2005-2006 models: 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 to secure the clutch end-plate.
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)
2005-2006 models: 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)
2005-2006 models: 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)
2005-2006 models: 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.
1ST and 2ND CLUTCH END-PLATES
3RD and 4TH CLUTCH END-PLATES
16. Install the new clutch end-plate, then 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 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: 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. 2005-2006 models: 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: 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- 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. 2005-2006 models: 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. 2005-2006 models: 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 to secure the clutch end-plate.
21. Check that the clutch piston moves by applying air pressure into fluid passage.