Part 2

Clutch Disassembly

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





1. Remove the snap ring (A), with a screwdriver (B).





2. Remove the 1st clutch end-plate (A), 1st clutch discs (B) (5), 1st clutch waved-plates (C) (5), disc spring (D), 1st-hold clutch plate B (E), 1st-hold clutch discs (F) (3), 1st-hold clutch waved-plates (G) (2), and 1st-hold clutch flat-plate (H) from the 1st/1st-hold clutch drum (I).
3. Make reference marks on the clutch waved-plates.





4. Remove the clutch end-plate (A), clutch discs (B) (7), clutch waved-plates (C) (3), and clutch flat-plates (D) (4) from the 2nd clutch drum (E).
5. Make reference marks on the clutch waved-plates.





6. Remove the clutch end-plate (A), clutch discs (B) (5), clutch waved-plates (C) (2), clutch flat-plates (D) (3), and disc spring (E) from the 3rd clutch drum (F).
7. Make reference marks on the clutch waved-plates.





8. Remove the clutch end-plate (A), clutch discs (B) (4), clutch waved-plates (C) (2), clutch flat-plates (D) (2), and disc spring (E) from the 4th clutch drum (F).
9. Make reference marks on the clutch waved-plates.





10. Remove the clutch end-plate (A), clutch discs (B) (5), clutch waved-plates (C) (2), clutch flat-plates (D) (3), and disc spring (E) from the 5th clutch drum (F).
11. Make reference marks on the clutch waved-plates.





12. Install the special tools.





13. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 1st, 2nd, and 4th clutches.





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





15. Set the special tool (A) on the spring retainer (B) of the 3rd and 5th clutches so the special tool works on the clutch return spring (C).





16. If either end of the special tool is not set over the clutch return spring end (A), the retainer may be damaged.





17. Compress the return spring until the snap ring can be removed.





18. Remove the snap ring with the snap ring pliers.





19. Remove the special tools.
20. Remove the snap ring (A), spring retainer (B), and return spring (C).





21. Wrap a shop rag around the clutch drum, and apply air pressure to the fluid passage to remove the piston. Place a finger tip on the other passage while applying air pressure.





22. Remove the 1st/1st-hold clutch piston (A) from the clutch drum (B), and remove the O-rings from the 1st clutch piston.





23. Remove the 1st-hold clutch piston (A) from the 1st clutch piston (B), and remove the O-rings from the 1st-hold clutch piston.





24. Remove the clutch piston, and remove the O-rings from the 2nd, 3rd, 4th, and 5th clutch pistons.

Clutch Inspection





1. Inspect the 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. If the spring retainer is worn or damaged, replace it.
5. Inspect the clutch discs, clutch plates, and clutch end plate for wear, damage, and discoloration.
Clutch Discs
Standard Thickness: 1.94 mm (0.076 inch)
Clutch Flat-plates and Clutch Waved-plates
Standard Thickness
1st clutch: 1.6 mm (0.063 inch)
1st-hold clutch: 1.8 mm (0.071 inch)
2nd clutch: 1.8 mm (0.071 inch)
3rd clutch: 2.0 mm (0.079 inch)
4th clutch: 1.8 mm (0.071 inch)
5th clutch: 1.6 mm (0.063 inch)
6. 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.
7. 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 clutch end-plate-to-top-disc clearance.
8. 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 of the 1st, 1st-hold 2nd, 4th, and 5th clutches about 60-degrees apart from the bottom while holding the waved-plate by its circumference, and rotate the 3rd clutch waved-plate about 72-degrees or 54-degrees apart from the bottom while holding the waved-plate by its circumference. The dial indicator should be at the top (E) of a phase difference. Do not rotate the waved-plate while holding its surface, always rotate it by holding its circumference.
4. Read the dial indicator. The dial indicator reads the phase difference (C) of the waved-plate between the bottom and top.
Standard Phase Difference
1st clutch: 0.17 - 0.30 mm (0.007 - 0.012 inch)
1st-hold clutch: 0.10 - 0.20 mm (0.004 - 0.008 inch)
2nd clutch: 0.11 - 0.21 mm (0.004 - 0.008 inch)
3rd clutch: 0.12 - 0.24 mm (0.005 - 0.009 inch)
4th clutch: 0.12 - 0.24 mm (0.005 - 0.009 inch)
5th clutch: 0.12 - 0.22 mm (0.005 - 0.009 inch)
5. Rotate the waved-plate of the 1st, 1st-hold, 2nd, 4th, and 5th clutches about 60-degrees, and the 3rd clutch waved-plate about 54-degrees or 72-degrees. The dial indicator should be at the bottom of a phase difference (F and H), and 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 the clutch waved-plate phase difference, if necessary.





2. Install the 1st-hold clutch piston in the 1st clutch piston, and install 1st/1st-hold clutch piston (A) in the 1st/1st-hold clutch drum (B). Do not install the O-rings on the clutch pistons during inspection.





3. Install the 1st-hold clutch flat-plate (A), alternately install the clutch discs (B) (3) and the 1st-hold clutch waved-plates (C) (2), then install the 1st-hold clutch plate B (D) with the flat side down in the direction shown.





4. Measure the 1st-hold clutch plate B-to-top-disc clearance with a feeler gauge (A) while pressing the 1st-hold clutch plate B down. Take measurements in at least three places, and use the average as the actual clearance.
5. If the clearance is out of standard, replace the 1st hold clutch plates and discs as a set, and recheck.





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





7. Install the clutch pistons in the 2nd, 3rd, 4th, and 5th clutch drums. Do not install the O-rings on the clutch pistons during inspection.





8. Starting with the 2nd clutch flat-plate, alternately install the flat-plates (A) (4) and discs (B) (4), and alternately install the waved-plates (C) (3) and discs (B) (3). Install the clutch end-plate (D) with the flat side down on the top disc.





9. Install the disc spring (A) in the 3rd clutch drum (B) in the direction shown. Starting with the 3rd clutch flat-plate, alternately install the flat-plates (C) (3) and discs (D) (3), and alternately install the waved-plates (E) (2) and discs (D) (2). Install the clutch end-plate (F) with the flat side down on the top disc.





10. Install the disc spring (A) in the 4th clutch drum (B) in the direction shown. Starting with the 4th clutch flat-plate, alternately install the flat-plates (C) (3) and discs (D) (3), and alternately install the waved-plates (E) (2) and discs (D) (2). Install the clutch end-plate (F) with the flat side down on the top disc.





11. Install the disc spring (A) in the 5th clutch drum (B) in the direction shown. Starting with the 5th clutch flat-plate, alternately install the flat-plates (C) (3) and discs (D) (3), and alternately install the waved-plates (E) (2) and discs (D) (2). Install the clutch end-plate (F) with the flat side down on the top disc.





12. Install the snap ring with a screwdriver to secure the clutch end-plate.





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





15. Release the clutch end-plate to lower the clutch end-plate, then put the special tool on the end-plate (A).
16. Press the special tool down with 150 - 160 N (15 - 16 kgf, 33 - 35 lbs.) (B) using a force gauge, and read the dial indicator (C).
17. The dial indicator reads the clearance (D) between the clutch end-plate and 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: 1.15 - 1.35 mm (0.045 - 0.053 inch)
2nd clutch: 1.05 - 1.25 mm (0.041 - 0.049 inch)
3rd clutch: 0.80 - 1.00 mm (0.031 - 0.039 inch)
4th clutch: 0.70 - 0.90 mm (0.028 - 0.035 inch)
5th clutch: 0.75 - 0.95 mm (0.030 - 0.037 inch)

1ST CLUTCH END-PLATES:

2ND CLUTCH END-PLATES:

3RD CLUTCH END-PLATES:

4TH and 5TH CLUTCH END-PLATES:

18. If the clearance is out of the service limit, select a new clutch end-plate from the table.

19. Install the 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 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 1st-hold clutch piston (B), and install the 1st-hold clutch piston in the 1st clutch piston (C).





3. Install the new O-rings (A) on the 1st clutch piston (B), and install the 1st/1st-hold clutch piston in the 1st/1st-hold clutch drum (C) while applying pressure and rotating to ensure proper seating. Do not pinch the O-ring.





4. Install the O-rings (A) on the 2nd, 3rd, 4th, and 5th clutch piston (B).
5. Install the clutch pistons in the clutch drums (C) while applying pressure and rotating to ensure proper seating. Do not pinch the O-ring.





6. Install the return spring (A) and spring retainer (B), and position the snap ring (C) on the spring retainer.





7. Install the special tools.





8. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 1st 2nd, and 4th clutches.





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





10. Set the special tool (A) on the spring retainer (B) of the 3rd and 5th clutches so the special tool works on the clutch return spring (C).





11. If either end of the special tool is not set over the clutch return spring end (A), the retainer may be damaged.





12. Compress the return spring until the snap ring can be installed.





13. Install the snap ring with the snap ring pliers.
14. Remove the special tools.





15. Install the 1st-hold clutch flat-plate (A), alternately install the clutch discs (B) (3) and the 1st-hold clutch waved-plates (C) (2) in the 1st/1st-hold clutch drum (D), then install the 1st-hold clutch plate B (E) with the flat side down in the direction shown.
16. Install the disc spring (F) on the 1st-hold clutch plate B in the direction shown. Starting with the 1st clutch waved-plate, alternately install the waved-plates (G) (5) and discs (H) (5), then install the clutch-end-plate (I) with the flat side down on the top disc.





17. Starting with the 2nd clutch flat-plate, alternately install the flat-plates (A) (4) and discs (B) (4) in the 2nd clutch drum (C), and alternately install the waved-plates (D) (3) and discs (B) (3). Install the clutch end-plate (E) with the flat side down on the top disc.





18. Install the disc spring (A) in the 3rd clutch drum (B) in the direction shown. Starting with the 3rd clutch flat-plate, alternately install the flat-plates (C) (3) and discs (D) (3), and alternately install the waved-plates (E) (2) and discs (D) (2). Install the clutch end-plate (F) with the flat side down on the top disc.





19. Install the disc spring (A) in the 4th clutch drum (B) in the direction shown. Starting with the 4th clutch flat-plate, alternately install the flat-plates (C) (2) and discs (D) (2), and alternately install the waved-plates (E) (2) and discs (D) (2). Install the clutch end-plate (F) with the flat side down on the top disc.





20. Install the disc spring (A) in the 5th clutch drum (B) in the direction shown. Starting with the 5th clutch flat-plate, alternately install the flat-plates (C) (3) and discs (D) (3), and alternately install the waved-plates (E) (2) and discs (D) (2). Install the clutch end-plate (F) with the flat side down on the top disc.





21. Install the snap ring with a screwdriver to secure
the clutch-end-plate.