Part 2

Clutch Inspection (Continued)

1. Inspect the 4th and 5th 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, 2nd, and 3rd 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 in.)
Clutch Plate:
1st Clutch:
Wave-plate: 1.6 mm (0.063 in.)
Flat-plate: 1.6 mm (0.063 in.)
2nd Clutch:
Wave-plate: 2.0 mm (0.079 in.)
Flat-plate; 2.0 mm (0.079 in.)
3rd Clutch:
Wave-plate: 1.6 mm (0.063 in.)
Flat-plate: 1.6 mm (0.063 in.)
4th Clutch (Wave-plate): 2.0 mm (0.079 in.)
5th Clutch (Wave-plate): 2.0 mm (0.079 in.)

7. 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.
8. If any plate is worn, damaged, or discolored, replace the damaged plate with the new plate, and inspect the other wave plates for a phase difference. If the clutch plate is replaced, inspect the clearance between the clutch end-plate and the top disc.
9. If the clutch end-plate is worn, damaged, or discolored, inspect the 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: 0.10 - 0.20 mm (0.004 - 0.008 in.)
3rd Clutch: 0.10 - 0.20 mm (0.004 - 0.008 in.)
4th Clutch: 0.10 - 0.20 mm (0.004 - 0.008 in.)
5th Clutch: 0.10 - 0.20 mm (0.004 - 0.008 in.)

5. Rotate the wave-plate about 60°. The dial indicator should be at the bottom of a phase difference (F and G), and 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 the two values of the three measurements are within the standard, the wave plate is OK. If the two values 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 end-plate for wear and damage, and inspect clutch wave-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). Install the clutch flat-plate (C), then starting with the clutch disc, alternately install the clutch discs (D) (5) and clutch wave plates (E) (4), then install the clutch end-plate (F) with the flat side toward the disc.





4. Install the waved spring (A) in the 2nd clutch drum (B). Install the flat-plate (C), then starting with the clutch disc, alternately install the clutch discs (D) (6) and wave-plates (E) (5), then install the clutch end-plate (F) with the flat side toward the disc.





5. Install the waved spring (A) in the 3rd clutch drum (B). Install the clutch flat-plate (C), then starting with the clutch disc, alternately install the clutch discs (D) (6) and clutch wave plates (E) (5), then install the clutch end-plate (F) with the flat side toward the disc.





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





7. Install the waved spring (A) in the 5th clutch drum (B). Starting with the clutch wave-plate, alternately install the clutch wave-plates (C) (4) and clutch discs (D) (4), then install the clutch end-plate (E) with the flat side toward the disc.





8. Install the snap ring with a screwdriver.





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 the clutch end-plate, then put the clutch spring compressor attachment on the end-plate (A).





12. Press the clutch spring compressor attachment down with 150 - 160 N (15 - 16 kgf, 33 - 35 lbf) using a force gauge, and read the dial indicator (B). The dial indicator reads the clearance (C) between the clutch end-plate and the top disc (D). Take measurements in at least three places, and use the average as the actual clearance.

Clearance between the Clutch End-plate and the Top Disc:
Service Limit:
1st Clutch: 1.38 - 1.58 mm (0.054 - 0.062 in.)
2nd Clutch: 1.14 - 1.34 mm (0.045 - 0.053 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 table.

1ST CLUTCH END-PLATES:

2ND CLUTCH END-PLATES:

3RD CLUTCH END-PLATES:

4TH and 5TH CLUTCH END-PLATES:

14. 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 new O-rings (A) on the 4th and 5th clutch piston (B).





3. 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).





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 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 clutch spring compressor attachment and clutch spring compressor bolt assembly.





7. Be sure the clutch spring compressor attachment (A) is adjusted to have full contact with the spring retainer (B) on the 4th and 5th clutches.





8. Set the clutch spring compressor attachment (A) on the spring retainer (B) of the 1st, 2nd, and 3rd clutches in such a way that it compresses the clutch return spring (C).





9. If either end of the clutch spring compressor attachment 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 clutch spring compressor attachment and clutch spring compressor bolt assembly.
13. Install the waved spring (A) in the 1st clutch drum (B). Install the clutch flat-plate (C), then starting with the clutch disc, alternately install the clutch discs (D) (5) and clutch wave-plates (E) (4), then install the clutch end-plate (F) with the flat side toward the disc.





14. Install the waved spring (A) in the 2nd clutch drum (B). Install the flat-plate (C), then starting with the clutch disc, alternately install the clutch discs (D) (6) and wave-plates (E) (5), then install the clutch end-plate (F) with the flat side toward the disc.





15. Install the waved spring (A) in the 3rd clutch drum (B). Install the clutch flat-plate (C), then starting with the clutch disc, alternately install the clutch discs (D) (6) and clutch wave-plates (E) (5), then install the clutch end-plate (F) with the flat side toward the disc.





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





17. Install the waved spring (A) in the 5th clutch drum (B). Starting with the clutch wave-plate, alternately install the clutch wave-plates (C) (4) and clutch discs (D) (4), then install the clutch end-plate (E) with the flat side toward the disc.





18. Install the snap ring with a screwdriver.





19. Check that the clutch piston moves by applying air pressure into fluid passage.