CLUTCH COMPONENT ASSEMBLY

id051700663700


Structural view

bcw7za00000010

1
Drum and shaft component
2
High clutch piston
3
O-ring (outer diameter approx. 53.2 mm {2.09 in}, thickness approx. 1.6 mm {0.063 in})
4
Springs and retainer component (outer diameter approx. 78.5 mm {3.09 in})
5
Seal plate
6
Snap ring (outer diameter approx. 56.5 mm {2.22 in})
7
Driven plate (inner diameter approx. 94.1 mm {3.70 in})
8
Drive plate (outer diameter approx. 111.7 mm {4.398 in})
9
Retaining plate (inner diameter approx. 94.1 mm {3.70 in})
10
Snap ring (outer diameter approx. 122.3 mm {4.815 in}) (selection)
11
Wave spring
12
Driven plate (inner diameter approx. 135.2 mm {5.323 in})
13
Drive plate (outer diameter approx. 149.9 mm {5.902 in})
14
Retaining plate (inner diameter approx. 135.2 mm {5.323 in})
15
Snap ring (outer diameter approx. 158.8 mm {6.252 in} (selection)


Assembly Procedure

1.  Assemble the high clutch piston using the following procedure:

(1)  Apply ATF (ATF FZ) to the high clutch piston lip.
(2)  Assemble the high clutch piston.
bcw6ja00000383
bcw6ja00000384

2.  Assemble the O-ring using the following procedure:

Caution
•  If a O-ring is reused it could cause ATF leakage, therefore use a new O-ring.
(1)  Apply ATF (ATF FZ) to the new O-ring.
(2)  Assemble the new O-rings.
Note
•  O-ring size: Outer diameter approx. 53.2 mm {2.09 in}, thickness approx. 1.6 mm {0.063 in}
bcw7za00000008
bcw7za00000009

3.  Assemble the springs and retainer component.

Note
•  Springs and retainer component size: Outer diameter approx. 78.5 mm {3.09 in}
bcw6ja00000385
bcw6ja00000386

4.  Assemble the seal plate using the following procedure:

(1)  Apply ATF (ATF FZ) to the seal plate lip.
(2)  Assemble the seal plate.
bcw6ja00000387
bcw6ja00000388

5.  Assemble the snap ring using the following procedure:

Note
•  Snap ring size: Outer diameter approx. 56.5 mm {2.22 in}
(1)  Set the snap ring to the top of the seal plate.
bcw6ja00000389
bcw6ja00000390
(2)  Install the SSTs.
bcw6ja00000651
bcw6ja00000652
(3)  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.
bcw6ja00000653
A  :Press
(4)  Press down the SSTs using the press until the snap ring groove of the drum and shaft component comes out.
Caution
•  If the press is pressed down excessively, surrounding parts could be damaged.Stop pressing down when the snap ring groove of the drum and shaft component comes out.
bcw6ja00000654
A  :Snap ring groove
(5)  Assemble the snap ring.
Caution
•  After assembling the snap ring, verify that the snap ring is securely inserted into the bottom of the snap ring groove.
bcw6ja00000656
A  :Snap ring
(6)  Take the SSTs and part off the press.
bcw6ja00000652
(7)  Remove the SSTs.
bcw6ja00000651

6.  Assemble the drive plates and driven plates using the following procedure:

Note
•  Drive plate size: Outer diameter approx. 111.7 mm {4.398 in}
•  Driven plate size: Inner diameter approx. 94.1 mm {3.70 in}
(1)  Apply ATF (ATF FZ) to the drive plates and driven plates.
Caution
•  If the drive plate is replaced with a new one, immerse it in ATF (ATF FZ) for 2 h or more to permeate the facing with ATF.
(2)  Assemble the drive plates and driven plates.
Assembly order
Driven plate—drive plate—driven plate—drive plate—driven plate—drive plate—driven plate—drive plate
bcw6ja00000396
A  :Drive plate
B  :Driven plate
bcw6ja00000397

7.  Assemble the retaining plate.

Note
•  Retaining plate size: Inner diameter approx. 94.1 mm {3.70 in}
bcw6ja00000398
bcw6ja00000399

8.  Assemble the snap ring using the following procedure:

Note
•  Snap ring size: Outer diameter approx. 122.3 mm {4.815 in}
(1)  Measure the high clutch clearance and select the appropriate snap ring. (See HIGH CLUTCH CLEARANCE MEASUREMENT/ADJUSTMENT.)
Note
•  If the snap ring is assembled for the high clutch clearance measurement/adjustment, the following snap ring assembly procedure is not necessary.
(2)  Assemble the selected snap ring in Step (1).
Caution
•  After assembling the snap ring, verify that the snap ring is securely inserted into the bottom of the snap ring groove.
bcw6ja00000400
A  :Selection
bcw6ja00000401

9.  Assemble the wave spring.

bcw6ja00000402
bcw6ja00000403

10.  Assemble the drive plates and driven plates using the following procedure:

Note
•  Drive plate size: Outer diameter approx. 149.9 mm {5.902 in}
•  Driven plate size: Inner diameter approx. 135.2 mm {5.323 in}
(1)  Apply ATF (ATF FZ) to the drive plates and driven plates.
Caution
•  If the drive plate is replaced with a new one, immerse it in ATF (ATF FZ) for 2 h or more to permeate the facing with ATF.
(2)  Assemble the drive plates and driven plates.
Assembly order
Driven plate—drive plate—driven plate—drive plate—driven plate—drive plate
bcw6ja00000404
A  :Drive plate
B  :Driven plate
bcw6ja00000405

11.  Assemble the retaining plate.

Note
•  Retaining plate size: Inner diameter approx. 135.2 mm {5.323 in}
bcw6ja00000406
bcw6ja00000407

12.  Assemble the snap ring using the following procedure:

Note
•  Snap ring size: Outer diameter approx. 158.8 mm {6.252 in}
(1)  Measure the low clutch clearance and select the appropriate snap ring. (See LOW CLUTCH CLEARANCE MEASUREMENT/ADJUSTMENT.)
Note
•  If the snap ring is assembled for the low clutch clearance measurement/adjustment, the following snap ring assembly procedure is not necessary.
(2)  Assemble the selected snap ring in Step (1) to the position shown in the figure.
Caution
•  Assemble so that the end gap of the snap ring is positioned diagonally opposed to the end gap of the snap ring for the high clutch.
•  After assembling the snap ring, verify that the snap ring is securely inserted into the bottom of the snap ring groove.
bcw6ja00000408
A  :Selection
bcw6ja00000409
A  :Snap ring (low clutch)
B  :Snap ring (high clutch)

13.  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.
bcw6ja00000359
Compressed air pressure
0.39—0.44 MPa {4.0—4.4 kgf/cm2, 57—63 psi}
•  If there is any malfunction, perform disassembly again, verify the cause and repair the applicable part.(See CLUTCH COMPONENT 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.
bcw6ja00000360
Compressed air pressure
0.39—0.44 MPa {4.0—4.4 kgf/cm2, 57—63 psi}
•  If there is any malfunction, perform disassembly again, verify the cause and repair the applicable part. (See CLUTCH COMPONENT DISASSEMBLY.)
(6)  Remove the clutch component.
bcw6ja00000357
(7)  Remove the thrust washer.
bcw6ja00000361
(8)  Take the oil pump off the rubber plates.
azzjjw00001202