CLUTCH COMPONENT DISASSEMBLY


id051700660700


Structural view

bcw6ja00001145

1
Snap ring
2
Retaining plate
3
Drive plate
4
Driven plate
5
Wave spring
6
Snap ring
7
Retaining plate
8
Drive plate
9
Driven plate
10
Snap ring
11
Seal plate
12
Springs and retainer component
13
O-ring
14
High clutch piston
15
Drum and shaft component


Disassembly Procedure

1.  Perform a simple inspection of the low clutch and high clutch using the following procedure:

(1)  Set the oil pump on the workbench as shown in the figure.
Note
•  Using the rubber plates, adjust the alignment surface of the oil pump with the transaxle case so that it is level.
azzjjw00000802
A  :Rubber plate
(2)  Assemble the thrust washer to the clutch component using the following procedure:
Note
•  Thrust washer size: Inner diameter approx. 58.7 mm {2.31 in}
1)  To prevent the thrust washer from dropping out, apply ATF (ATF FZ) to the thrust washer.
2)  Assemble the thrust washer.
bcw6ja00000355
bcw6ja00000356
(3)  Assemble the parts assembled together in Step (2) to the oil pump.
bcw6ja00000357
bcw6ja00000358
(4)  Blow compressed air into the oil passage shown in the figure and verify the operation condition of the low clutch.
Warning
•  Always wear protective eye wear when using the air compressor. Otherwise, ATF or dirt particles blown off by the air compressor could get into the eyes.
Caution
•  To prevent damage to parts, always use an air compressor which is adjusted to the indicated pressure.
bcw6ja00000410
Compressed air pressure
0.39—0.44 MPa {4.0—4.4 kgf/cm2, 57—63 psi}
•  If there is a malfunction, verify the cause and repair the applicable part after disassembly.
(5)  Blow compressed air into the oil passage shown in the figure and verify the operation condition of the high clutch.
Warning
•  Always wear protective eye wear when using the air compressor. Otherwise, ATF or dirt particles blown off by the air compressor could get into the eyes.
Caution
•  To prevent damage to parts, always use an air compressor which is adjusted to the indicated pressure.
bcw6ja00000411
Compressed air pressure
0.39—0.44 MPa {4.0—4.4 kgf/cm2, 57—63 psi}
•  If there is a malfunction, verify the cause and repair the applicable part after disassembly.
(6)  Remove the clutch component.
bcw6ja00000357
(7)  Remove the thrust washer.
bcw6ja00000361
(8)  Take the oil pump off the rubber plates.
azzjjw00001202

2.  Remove the snap ring.

bcw6ja00000362

3.  Remove the retaining plate.

bcw6ja00000363

4.  Remove the drive plates and driven plates.

bcw6ja00000364

A  :Drive plate
B  :Driven plate

5.  Remove the wave spring.

bcw6ja00000365

6.  Remove the snap ring.

bcw6ja00000366

7.  Remove the retaining plate.

bcw6ja00000367

8.  Remove the drive plates and driven plates.

bcw6ja00000368

A  :Drive plate
B  :Driven plate

9.  Remove the snap ring using the following procedure:

(1)  Install the SSTs.
bcw6ja00000642
bcw6ja00000643
(2)  Set the SSTs and part to the press as shown in the figure.
Caution
•  Set the SST (49 D019 003) to the center of the seal plate.
bcw6ja00000644
A  :Press
(3)  Press the SSTs down using a press until there is no longer any spring force from the springs and retainer component applied to the snap ring.
Caution
•  If the press is pressed excessively, surrounding parts could be damaged.Stop pressing if a gap appears between the snap ring and seal plate.
bcw6ja00000645
A  :Snap ring
B  :Seal plate
C  :Gap
(4)  Remove the snap ring from the snap ring groove.
bcw6ja00000646
(5)  Take the SSTs and part off the press.
bcw6ja00000643
(6)  Remove the SSTs.
bcw6ja00000642
(7)  Remove the snap ring removed from the snap ring groove.
bcw6ja00000374

10.  Remove the seal plate.

bcw6ja00000375

11.  Remove the springs and retainer component.

bcw6ja00000376

12.  Remove the O-ring.

bcw7za00000007

13.  Remove the high clutch piston using the following procedure:

(1)  Set the oil pump on the workbench as shown in the figure.
Note
•  Using the rubber plates, adjust the alignment surface of the oil pump with the transaxle case so that it is level.
azzjjw00000802
A  :Rubber plate
(2)  Assemble the thrust washer to the drum and shaft component using the following procedure:
Note
•  Thrust washer size: Inner diameter approx. 58.7 mm {2.31 in}
1)  To prevent the thrust washer from dropping out, apply ATF (ATF FZ) to the thrust washer.
2)  Assemble the thrust washer.
bcw6ja00000355
bcw6ja00000356
(3)  Assemble the parts assembled together in Step (2) to the oil pump.
bcw6ja00000377
bcw6ja00000378
(4)  Blow compressed air into the oil passage shown in the figure.
Warning
•  Always wear protective eye wear when using the air compressor. Otherwise, ATF or dirt particles blown off by the air compressor could get into the eyes.
Caution
•  To prevent damage to parts, always use an air compressor which is adjusted to the indicated pressure.
bcw6ja00000379
Compressed air pressure
0.39—0.44 MPa {4.0—4.4 kgf/cm2, 57—63 psi}
(5)  Remove the high clutch piston removed from the drum and shaft component.
bcw6ja00000380
(6)  Remove the drum and shaft component.
bcw6ja00000381
(7)  Remove the thrust washer.
bcw6ja00000361
(8)  Take the oil pump off the rubber plates.
azzjjw00001202

14.  Clean the disassembled parts. (See AUTOMATIC TRANSAXLE CLEANING.)

15.  Perform the following inspection and replace a malfunctioning part with a new one.

•  Visual inspection of parts (See VISUAL INSPECTION OF PARTS.)
•  Low clutch inspection (See LOW CLUTCH INSPECTION.)
•  High clutch inspection (See HIGH CLUTCH INSPECTION.)