Clutch Assembly

CLUTCH ASSEMBLY

Preparation

SST

Preinspection
Reverse, forward, coasting clutch operation

1. Set the clutch assemblies onto the oil pump.
2. Check the clutch operation by applying compressed air through the fluid passages shown.

Air pressure:
392 kPa (4.0 kgf/cm2, 57 psi) max.

Clutch clearance
Reverse clutch

Note: Make several measurements and calculate the average value.

1. Measure the clearance between the retaining plate and the snap ring.

Clearance:
1.0 - 1.3 mm (0.039 - 0.051 in)

2. If not as specified, replace parts as necessary.
3. Select and install the correct snap ring when assembling.

Forward clutch

Note: Make several measurements and calculate the average value.

1. Measure the clearance between the retaining plate and the snap ring.

Clearance:
1.0 - 1.2 mm (0.039 - 0.047 in)

2. If not as specified, replace parts as necessary.

3. Select and install the correct snap ring when assembling.

Coasting clutch
1. Remove the snap ring, retaining plate, drive plates, driven plates, and dished plate of the forward clutch.

Note: Make several measurements and calculate the average value.

2. Measure the clearance between the retaining plate and the snap ring.

Clearance:
1.0 - 1.2 mm (0.039 - 0.047 in)

3. If not as specified, replace parts as necessary.
4. Select and install the correct snap ring when assembling.

Disassembly / Inspection / Assembly
1. Disassemble in the order shown in the figure, referring to Disassembly note.
2. Assemble in the reverse order of disassembly, referring to Assembly procedure.

Clutch Assembly:

Disassembly note
Snap ring (coasting clutch)

1. Install the SSTs in the coasting clutch drum as shown.

Caution: Depress the spring and retainer only enough to remove the snap ring.

2. Compress the spring and retainer assembly.

Caution: Do not deform the snap ring when removing it.

3. Remove the snap ring by using a screwdriver.
4. Remove the SSTs, and remove the spring and retainer assembly.

Coasting clutch drum
Remove the coasting clutch drum from the reverse and forward drum by applying compressed air through the fluid passage.

Air pressure:
392 kPa (4.0 kgf/cm2, 57 psi) max.

Coasting piston

Remove the coasting clutch piston from the coasting clutch drum by applying compressed air through the fluid passage.

Air pressure:
392 kPa (4.0 kgf/cm2, 57 psi) max.

Snap ring (reverse clutch)

1. Install the SSTs in the reverse and forward drum as shown.

Caution: Depress the piston return spring only enough to remove the snap ring.

2. Compress the piston return spring.

Caution: Do not deform the snap ring when removing it.

3. Remove one end of the snap ring from the groove by using snap ring pliers.

4. Remove the SSTs from the reverse and forward drum.

Caution: Do not deform the snap ring when removing it.

5. Remove the snap ring by using a screwdriver.

Reverse piston

1. Place the reverse and forward drum on the oil pump.
2. Remove the reverse piston by applying compressed air through the fluid passage.

Air pressure:
392 kPa (4.0 kgf/cm2, 57 psi) max.

Inspection
Drive plates

1. Measure the facing thickness in three places and calculate the average value.

Standard: 1.6 mm (0.063 in)
Minimum: 1.4 mm (0.055 in)

2. If not within specification, replace the drive plates.

Spring and retainer assembly

Note: Do not compress the spring when measuring it with vernier calipers.

1. Measure the free length of the spring and check for deformation.

Free length:
20.45 mm (0.805 in)

2. If not within specification, replace the spring and retainer assembly.

Reverse piston
1. Verify that there is no air leakage when applying compressed air through the oil hole opposite the return spring.
2. Verify that there is air flow when applying compressed air through the oil hole on the return spring side.

Air pressure:
392 kPa (4.0 kgf/cm2, 57 psi) max.

Coasting piston

1. Verify that there is no air leakage when applying compressed air through the oil hole opposite the return spring.
2. Verify that there is air flow when applying compressed air through the oil hole on the return spring side.

Air pressure:
392 kPa (4.0 kgf/cm2, 57 psi) max.

Reverse and forward drum

1. Install the reverse piston.

Seal ring inner diameter
Inner seal: 140.7 mm (5.539 in)
Outer seal: 166.0 mm (6.535 in)

1) Apply ATF to inner and outer faces of the seals and install them to the reverse piston.
2) Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the reverse and forward drum.

3) Install the reverse piston by pushing evenly around the circumference, being careful not to damage the outer seal.

2. Install the piston return spring.
3. Install the return spring stop.

Caution: Do not deform the snap ring when installing it.

4. Install the snap ring halfway down the reverse and forward drum as shown.

5. Install the SSTs on the reverse and forward drum.

Caution: Depress the piston return spring only enough to install the snap ring.

6. Compress the piston return spring assembly.

Caution: Do not deform the snap ring when installing it.

7. Install the snap ring by using a screwdriver.
8. Remove the SSTs.

9. Install the dished plate with the dished side facing the piston.

Caution: Installation order: Driven-Drive-Driven-Drive

10. Install the drive and driven plates.
11. Install the retaining plate.
12. Install the snap ring by using a screwdriver.

13. Measure the reverse clutch clearance.
1) Measure the clearance between the retaining plate and the snap ring.
2) If the clearance is not within specification, adjust it by selecting a proper snap ring from below.

Reverse clutch clearance:
2.1 - 2.4 mm (0.083 - 0.094 in)

Snap ring sizes

Coasting Clutch

1. Install the coasting clutch drum.
1) Apply ATF to inner and outer faces of the seals, and install them onto the coasting clutch drum.

Seal ring inner diameter
Inner seal: 56.1 mm (2.209 in)
Outer seal: 117.02 mm (4.607 in)

2) Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the reverse and forward drum.

3) Install the coasting clutch drum into the reverse and forward drum as shown.
4) Install the coasting piston by pushing evenly around the circumference, being careful not to damage the outer seal.

2. Install the coasting piston.
1) Apply ATF to inner and outer faces of the seals and install them onto the coasting piston.

Seal ring inner diameter
Outer seal: 104.02 mm (4.095 in)

2) Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the coasting clutch drum.

3) Install the coasting piston by pushing evenly around the circumference, being careful not to damage the outer seal.

3. Install the spring and retainer assembly.
4. Install the SSTs in the coasting clutch.

Caution: Depress the spring and retainer assembly only enough to install the snap ring.

5. Compress the spring and retainer assembly.

Caution:
^ Do not align the snap ring end gap with the spring and retainer stop.
^ Do not deform the snap ring when installing it.

6. Install the snap ring by using a screwdriver.
7. Remove the SSTs.

8. Install the dished plate with the dished side downward.

Caution: Installation order: Driven-Drive-Driven-Drive

9. Install the drive and driven plates.
10. Install the retaining plate.
11. Install the snap ring.

12. Measure the coasting clutch clearance.

Note: Make several measurements and calculate the average value.

1) Measure the clearance between the snap ring and the retaining plate.

Coasting clutch clearance:
1.0 - 1.2 mm (0.039 - 0.047 in)

2) If the clearance is not within specification, adjust it by selecting a proper snap ring from below.

Snap ring sizes

Forward clutch

1. Install the dished plate with the dished side downward.

Caution: Installation order: Driven-Drive-Driven-Drive-Driven-Drive

2. Install the drive and driven plates.

3. Install the retaining plate.

Caution: Do not deform the snap ring when installing it.

4. Install the snap ring.
5. Measure the forward clutch clearance.

Note: Make several measurements and calculate the average value.

1) Measure the clearance between the snap ring and the retaining plate of the forward clutch.

Forward clutch clearance:
1.0 - 1.2 mm (0.039 - 0.047 in)

2) If the clearance is not within specification, adjust it by selecting a proper snap ring from below.

Snap ring sizes

6. Check the clutch operation as follows.
1) Set the clutch assembly onto the oil pump.
2) Check the clutch operation by applying compressed air through the fluid passages shown.

Air pressure:
392 kPa (4.0 kgf/cm2, 57 psi) max.

7. Apply petroleum jelly to the thrust bearings, and secure them on the reverse forward drum.

Thrust bearing outer diameter
Oil pump side: 86.1 mm (3.390 in)
Small sun gear and one-way clutch side:
56.1 mm (2.209 in)