CLUTCH DRUM COMPONENT AND F4 ONE-WAY CLUTCH COMPONENT ASSEMBLY

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Components

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1
Bearing race
2
Thrust needle spring
3
Seal ring
4
Input shaft component
5
O-ring
6
C1 clutch position
7
C4 clutch position
8
Piston return spring
9
O-ring
10
C1 clutch seal plate
11
Snap ring
12
Driven plate
13
Drive plate
14
Retaining plate
15
Snap ring
16
Driven plate
17
Driven plate
18
Drive plate
19
Retaining plate
20
Snap ring
21
Bearing race
22
Thrust needle bearing
23
Clutch hub
24
Thrust washer
25
F4 one-way clutch

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1
Snap ring
2
C3 clutch seal plate
3
Piston return spring
4
O-ring
5
C3 clutch piston component
6
O-ring
7
C2, C3 clutch drum
8
O-ring
9
C2 clutch piston
10
C2 clutch piston return spring
11
O-ring
12
C2 clutch seal plate
13
Snap ring
14
Driven plate
15
Drive plate
16
Retaining plate
17
Snap ring
18
Snap ring
19
Bearing race
20
Thrust bearing
21
Thrust washer
22
Clutch hub
23
Retaining plate
24
Thrust needle bearing
25
Clutch hub component
26
Drive plate
27
Driven plate
28
Retaining plate
29
Driven plate
30
Sleeve
31
Snap ring


Assembly Procedure

1.  Apply ATF to the new O-rings.

2.  Install the O-rings to the C2, C3 clutch drum.

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3.  Apply ATF to the new O-rings.

4.  Install the O-rings to the C3 clutch piston component.

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5.   Apply ATF to the C2, C3 clutch drum and the C3 clutch piston component.

Caution
•  Do not damage the O-ring.

6.  Install the C2, C3 clutch drum to the C3 clutch piston component.

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7.  Apply ATF to the seal plate and the piston return spring.

Caution
•  Do not damage the O-ring.

8.  Install the seal plate and the piston return spring to the C3 clutch hub component.

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9.  Install the SST using a M10-1.25 bolt with a length of 100 mm as shown in the figure to compress the piston return spring.

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Caution
•  Do not expand the snap ring too much.

10.  Remove the snap ring using snap ring pliers.

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11.  Apply ATF to the new O-rings.

12.   Install the O-rings to the C2 clutch piston.

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13.  Apply ATF to the new O-rings.

14.  Install the O-rings to the C2 clutch seal plate.

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15.  Apply ATF to the C2 clutch piston and the C2, C3 clutch drum.

Caution
•  Do not damage the O-ring.

16.  Install the C2 clutch piston and the C2, C3 clutch drum.

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17.  Apply ATF to the C2 clutch seal plate and the C2, C3 clutch drum.

18.  Install the C2 clutch seal plate and the C2 clutch piston return spring to the C2, C3 clutch drum.

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19.  Install the SST as shown in the figure, and compress the C2 clutch piston return spring.

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Caution
•  Do not expand the snap ring too much.

20.  Install the snap ring using snap ring pliers.

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21.  Apply ATF to the driven plate (C2) and the drive plate (C2) and the retaining plate (C2).

22.  Install the driven plate (C2), the drive plate (C2), the retaining plate (C2) to the C2, C3 clutch drum.

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Caution
•  Inspect the number of drive and driven plates.

23.  Using a flathead screwdriver, install the snap ring (C2) to the C2, C3 clutch drum.

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Caution
•  When installing the snap ring, set the end gap of the snap ring as shown in the figure.

24.  Measure the retaining plate travel distance at both ends across the diameter using a dial gauge while blowing compressed air into the oil passage as shown in the figure, and calculate the average value. Verify that the piston moves smoothly.

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Air pressure
200 kPa (2 kgf/cm2, 28 psi)

Identification mark

Thickness (mm {in})
0
2.95—3.05 {0.016—0.120}
1
3.05—3.15 {0.120—0.124}
2
3.15—3.25 {0.124—0.128}
3
3.25—3.35 {0.128—0.132}
4
3.35—3.45 {0.132—0.136}
5
3.45—3.55 {0.136—0.140}
6
3.55—3.65 {0.140—0.144}
7
3.65—3.75 {0.144—0.148}
8
3.75—3.85 {0.148—0.152}

Caution
•  If the C2 clutch pack clearance exceeds the maximum specification, select another retaining plate.

25.  Using a flathead screwdriver, install the snap ring (C3) to the C2, C3 clutch drum.

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Caution
•  When installing the snap ring, set the end gap of the snap ring as shown in the figure.

26.  Apply ATF to the retaining plate (C3), the driven plate (C3), the drive plate (C3).

Caution
•  Inspect the number of drive and driven plates.

27.  Install the retaining plate (C3) and the driven plate (C3) and the drive plate (C3) and the sleeve to the C2, C3 clutch drum.

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Caution
•  When installing the snap ring, set the end gap of the snap ring as shown in the figure.

28.  Using a flathead screwdriver, install the snap ring (C3) to the C2, C3 clutch drum.

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29.  Measure the driven plate travel distance of the reverse piston travel distance and driven plate at the both ends across the diameter using a dial gauge while blowing compressed air into the oil passage as shown in the figure, and calculate the average value. Verify that the piston moves smoothly.

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Air pressure
200 kPa (2 kgf/cm2, 28 psi)
Standard travel distance A
1.62—2.68 mm {0.06—0.10 in}
Standard travel distance B
1.22—1.67 mm {0.05—0.06 in}
Standard gap
0.40—0.70 mm {0.01—0.03 in}

Identification mark

Thickness (mm {in})
0
2.35—2.45 {0.093—0.096}
1
2.45—2.55 {0.096—0.100}
2
2.55—2.65 {0.100—0.104}
3
2.65—2.75 {0.104—0.108}
4
2.75—2.85 {0.108—0.112}
5
2.85—2.95 {0.112—0.116}
6
2.95—3.05 {0.116—0.120}
7
3.05—3.15 {0.120—0.124}
8
3.15—3.25 {0.124—0.128}
9
3.25—3.35 {0.128—0.132}
A
3.35—3.45 {0.132—0.136}
B
3.45—3.55 {0.136—0.140}

Caution
•  If the C3 clutch pack clearance exceeds the maximum specification, select another retaining plate.

30.  Apply ATF to the sliding surface of the new seal ring input shaft.

Caution
•  Do not expand the seal ring too much.
•  Be careful not to shorten the seal rings too much, when installing them.

31.  Compress the seal rings as shown in the figure and install them to the input shaft component.

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Note
•  Verify that oil seal rings rotate smoothly after installing them.

32.  Apply ATF to the new D-ring.

33.   Install the D-ring to the C4 clutch seal plate.

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34.  Apply ATF to the new O-ring.

35.   Install the O-ring to the input shaft component.

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36.  Apply ATF to the C1 clutch piston and the C4 clutch piston to the input shaft component.

37.  Install the C1 clutch piston and the C4 clutch piston to the input shaft component.

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38.  Apply ATF to the C1 clutch seal plate and the input shaft component.

39.  Install the C1 clutch seal plate and the piston return spring to the input shaft component.

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Caution
•  Do not damage the D-ring.

40.  Place the SST on the C1 clutch seal plate and compress the piston return spring with a press.

Caution
•  Do not expand the snap ring too much.

41.  Install the snap ring using snap ring pliers.

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42.  Apply ATF to the retaining plate (C4), the driven plate (C4), the drive plate (C4).

Caution
•  Inspect the number of drive and driven plates.

43.  Install the retaining plate (C4), the driven plate (C4), the drive plate (C4) to the input shaft component.

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44.  Using a flathead screwdriver, install the snap ring to the input shaft component.

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45.  Measure the retaining plate travel distance at both ends across the diameter using a dial gauge while blowing compressed air into the oil passage as shown in the figure, and calculate the average value. Verify that the piston moves smoothly.

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Air pressure
200 kPa (2 kgf/cm2, 28 psi)
Standard travel distance
0.02—1.01 mm {0.0008—0.0397 in}
Standard gap
0.4—0.7 mm {0.0158—0.0275 in}

Identification mark

Thickness (mm {in})
0
2.95—3.05 {0.116—0.120}
1
3.05—3.15 {0.120—0.124}
2
3.15—3.25 {0.124—0.128}
3
3.25—3.35 {0.128—0.132}
4
3.35—3.45 {0.132—0.136}
5
3.45—3.55 {0.136—0.140}
6
3.55—3.65 {0.140—0.144}
7
3.65—3.75 {0.144—0.148}
8
3.75—3.85 {0.148—0.152}
9
3.85—3.95 {0.152—0.156}

Caution
•  If the C4 clutch pack clearance exceedy the maximum specification, select another retaining plate.

46.  Apply ATF to the retaining plate (C1), the driven plate (C1), the drive plate (C1).

Caution
•  Inspect the number of drive and driven plates.

47.  Install the retaining plate (C1), the driven plate (C1), the drive plate (C1) to the input shaft component.

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48.  Using a flathead screwdriver, install the snap ring to the input shaft component.

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49.  Measure the retaining plate travel distance at both ends across the diameter using a dial gauge while blowing compressed air into the oil passage as shown in the figure, and calculate the average value. Verify that the piston moves smoothly.

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Air pressure
200 kPa (2 kgf/cm2, 28 psi)
Standard travel distance
0.14—0.17 mm {0.0056—0.0066 in}
Standard gap
0.56—0.86 mm {0.0221—0.0338 in}
Caution
•  If the C1 clutch pack clearance exceedy the maximum specification, select another retaining plate.

50.  Apply ATF to the F4 one-way clutch and the thrust washer.

51.  Install the F4 one-way clutch to the clutch hub.

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52.  Apply ATF to the bearing race.

53.  Install the bearing race to the C1, C4 clutch component.

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54.  Install the clutch hub to the C1, C4 clutch component.

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55.  Apply ATF to the bearing race.

56.  Install the bearing race to the C3 clutch piston component.

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57.  Install the C1, C4 clutch component to the C2, C3 clutch drum.

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58.  Apply ATF to the thrust bearing, the bearing race and the thrust washer.

59.  Install the thrust bearing, bearing race and thrust washer.

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60.  Install the clutch hub to the C3 clutch piston component.

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61.  Apply ATF to the thrust needle spring.

62.  Install the thrust needle spring to the clutch hub.

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63.  Apply ATF to the retaining plate.

64.  Install the retaining plate to the C3 clutch piston component.

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65.  Install the clutch hub component to the C3 clutch piston component.

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66.  Apply ATF to the retaining plate, the drive plate, the driven plate.

Caution
•  Inspect the number of drive and driven plates.

67.  Install the retaining plate (C3), the drive plate (C3), and the driven plate (C3) to the clutch hub component.

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68.  Using a flathead screwdriver, install the snap ring to the C3 clutch piston component.

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