Clutch Drum and Input Shaft Assembly

A960E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: INSPECTION

1. INSPECT NO. 4 ONE WAY CLUTCH ASSEMBLY

(a) Hold the coast clutch hub and turn the one way clutch assembly.

(b) Check that the one way clutch assembly turns freely clockwise and locks counterclockwise.

If there is a problem with the one way clutch, replace it.

2. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Using vernier calipers, measure the free length of the spring together with the spring seat.

Standard free length:

20.02 mm (0.788 in.)

(b) If the free length is shorter than the standard free length, replace the clutch return spring sub-assembly.

3. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Using vernier calipers, measure the free length of the spring together with the spring seat.

Standard free length:

21.03 mm (0.828 in.)

(b) If the free length is shorter than the standard free length, replace the clutch return spring sub-assembly.

4. INSPECT NO. 2 DIRECT CLUTCH DISC

(a) Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt.

(1) Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across a diameter while blowing air to the oil hole as shown in the illustration, and calculate the average.

HINT
Flange moving distance A = 0.24 to 1.12 mm (0.0094 to 0.0441 in.)

Pack clearance = Flange moving distance A - 0.03 mm (0.0012 in.)

Pack Clearance:

0.5 to 0.8 mm (0.020 to 0.031 in.)

NOTICE:
Install a selective flange {t = 3.4 mm (0.134 in.)} when measuring the moving distance (shaded area in the illustration).

(2) If the pack clearance is outside the specified range, select and install a clutch flange that brings the pack clearance within the specified range.

HINT
There are 9 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

Flange thickness:

6. INSPECT PACK CLEARANCE OF NO. 3 CLUTCH

(a) Inspect the pack clearance of the reverse clutch hub sub-assembly.

(1) Using a dial indicator, measure the reverse clutch piston stroke (distance A) and the moving distance (distance B) of the reverse clutch flange at both ends across a diameter while blowing air (392 kPa, 4 kgf/cm2, 57 psi) from the oil hole as shown in the illustration, and calculate the average.

HINT
Piston stroke A = 1.62 to 2.68 mm (0.0638 to 0.1055 in.)

Flange moving distance B = 1.22 to 1.67 mm (0.0480 to 0.0657 in.)

Pack clearance = Piston stroke A - Flange moving distance B - 0.02 mm (0.0008 in.)

Pack Clearance:

0.4 to 0.7 mm (0.016 to 0.028 in.)

NOTICE:
Install a selective flange {t = 2.8 mm (0.110 in.)} when measuring the moving distance (shaded area in the illustration).

(2) If the pack clearance is outside the specified range, select and install a clutch flange that brings the pack clearance within the specified range.

HINT
There are 12 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

Flange thickness:

7. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Using vernier calipers, measure the free length of the spring together with the spring seat.

Standard free length:

26.29 mm (1.035 in.)

(b) If the free length is shorter than the standard free length, replace the clutch return spring sub-assembly.

8. INSPECT COAST CLUTCH DISC

(a) Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt.

(b) If necessary, replace them.

NOTICE:
* If the linings of the discs are peeled off or discolored, or even a part of the printed numbers is damaged, replace all discs.
* Before assembling new discs, soak them in ATF for at least 15 minutes.
9. INSPECT PACK CLEARANCE OF NO. 1 CLUTCH

(a) Inspect the pack clearance of the No. 1 clutch.

(1) Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.

HINT
Flange moving distance A = 0.14 to 0.17 mm (0.0055 to 0.0067 in.)

Pack clearance = Flange moving distance A - 0.01 mm (0.00039 in.)

Pack Clearance:

0.56 to 0.86 mm (0.0220 to 0.0339 in.)

NOTICE:
Install a selective flange {t = 3.5 mm (0.138 in.)} when measuring the moving distance (shaded area in the illustration).

(2) If the pack clearance is outside the specified range, select and install a clutch flange that brings the pack clearance within the specified range.

HINT
There are 10 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

Flange thickness:

10. INSPECT NO. 1 CLUTCH DISC

(a) Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt.

(b) If necessary, replace them.

NOTICE:
* If the linings of the discs are peeled off or discolored, or even a part of the printed numbers is damaged, replace all discs.
* Before assembling new discs, soak them in ATF for at least 15 minutes.
11. INSPECT PACK CLEARANCE OF COAST CLUTCH

(a) Inspect the pack clearance of the coast clutch.

(1) Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.

HINT
Flange moving distance A = 0.02 to 1.01 mm (0.0008 to 0.0398 in.)

Pack clearance = Flange moving distance A - 0.01 mm (0.00039 in.)

Pack Clearance:

0.4 to 0.7 mm (0.0157 to 0.0276 in.)

NOTICE:
Install a selective flange {t = 3.5 mm (0.138 in.)} when measuring the moving distance (shaded area in the illustration).

(2) If the pack clearance is outside the specified range, select and install a clutch flange that brings the pack clearance within the specified range.

HINT
There are 10 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

Flange thickness:

12. INSPECT CLUTCH HUB SUB-ASSEMBLY

(a) Using a dial indicator, measure the inside diameter of the clutch hub bushing.

Standard inside diameter:

23.037 to 23.062 mm (0.907 to 0.908 in.)

(b) If the inside diameter is greater than the standard inside diameter, replace the clutch hub.

13. INSPECT NO. 3 CLUTCH DISC

(a) Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt.

Standard inside diameter:

33.312 to 33.337 mm (1.3115 to 1.3125 in.)

(b) If the inside diameter is greater than the standard inside diameter, replace the reverse clutch hub.