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DIRECT CLUTCH DISASSEMBLY/ASSEMBLY

D6E051719500A06

1. Perform the preinspection before disassembly. (See Direct Clutch Preinspection.)

2. Disassemble in the order indicated in the table.

3. Assemble in the reverse order of disassembly.

.

1 | Needle bearing (See Needle Bearing Disassembly Note.)
2 | Snap ring
3 | Retaining plate
4 | Drive and driven plate
5 | Snap ring (See Snap Ring (Direct clutch) Disassembly Note.)
6 | Seal plate
7 | Spring and retainer component
8 | Direct clutch piston (See Direct Clutch Piston Disassembly Note.)
9 | Direct clutch drum

## Needle Bearing Disassembly Note

1. Remove the needle bearing using the SST as shown in the figure.

## Snap Ring (Direct clutch) Disassembly Note

1. Install the SST as shown.

  Caution

  • Depress the seal plate only enough to remove the snap ring. Overpressing will damage the seal plate assembly edges.

2. Compress the seal plate.

3. Remove the snap ring.

4. Remove the SST, then remove the seal plate and spring and retainer component.

## Direct Clutch Piston Disassembly Note

1. Set the direct clutch drum onto the transaxle case.

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

Air pressure

  392-441 kPa {4.0-4.5 kgf/cm2, 57-63 psi}

## Assembly Procedure

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

Direct clutch drive plate thickness

  Standard: 1.80 mm {0.071 in}
  Minimum: 1.65 mm {0.065 in}

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

2. Measure the free length of the spring and inspect for deformation.

Direct clutch springs and retainer component free length

  Standard: 17.2 mm {0.677 in}
  Minimum: 15.2 mm {0.598 in}

  • If not within the specification, replace the spring and retainer.

3. Verify that there is airflow when applying compressed air through the fluid passage of direct clutch drum. (four locations)

Air pressure

  392-441 kPa {4.0-4.5 kgf/cm2, 57-63 psi}

4. Replace the direct clutch drum if damaged or malfunctioning.

5. Install the direct clutch.

  Caution

  • Installing the direct clutch piston may damage its seal. Carefully install the direct clutch piston by pushing evenly around the circumference.

  (1) Apply ATF to the circumference of the direct clutch piston seal, and install the piston in to the direct clutch drum.
  (2) Install the spring and retainer.
  (3) Apply ATF to the seal plate, and install it onto the direct clutch drum.
  (4) Install the SST as shown.

  Caution

  • Depress the seal plate only enough to install the snap ring. Overpressing will damage the seal plate assembly edges.

  (5) Compress the spring and retainer component and seal plate.
  (6) Install the snap ring.
  (7) Remove the SST.
  (8) Install the drive and driven plates in the following order.
  Driven-Drive-Driven-Driven-Drive
  (9) Install the retaining plate.
  (10) Install the snap ring.

6. Measure the direct clutch clearance.

  (1) Install the direct clutch in the transaxle case, and set the dial gauge.
  (2) Secure the direct clutch by lightly pressing down with a press or similar tool.
  (3) Apply compressed air to the part indicated in the figure and let the direct clutch piston stroke three times.
Air pressure

  392-441 kPa {4.0-4.5 kgf/cm2, 57-63 psi}

  (4) Apply compressed air and operate the direct clutch piston. Read the value when the indicator of the dial gauge stops.
  (5) Release the compressed air and read the dial gauge when the direct clutch piston is not operating.
  (6) Calculate the direct clutch clearance according to the following formula:
  step (4) value - step (5) value = direct clutch clearance.
  (7) Measure the clearances at four locations (90° apart) by following the steps from (3) to (6). Verify that the average value is within the specification below.
Direct clutch clearance

  Standard: 1.10-1.40 mm {0.043-0.055 in}

  • If not within the specification, remove the snap ring and measure its thickness.

  (8) Add the thickness to the average value calculated in step (7), and select the snap ring whose range includes the value.

Snap ring size for direct clutch clearance

Range mm {in} | Snap ring sizes mm {in}
--- | ---
2.424-2.624 {0.096-0.103} | 1.2 {0.047}
2.624-2.824 {0.104-0.111} | 1.4 {0.055}
2.824-3.024 {0.112-0.119} | 1.6 {0.063}
3.024-3.224 {0.120-0.126} | 1.8 {0.071}
3.224-3.424 {0.127-0.134} | 2.0 {0.079}
3.424-3.624 {0.135-0.142} | 2.2 {0.087}

  (9) Install the selected snap ring and perform steps (2) to (7) again. Verify that the calculated value satisfies the clearance specification.

7. Inspect the direct clutch operation.

  (1) Install the direct clutch drum to the transaxle case.
  (2) Inspect the direct clutch operation by applying compressed air as shown.
Air pressure

  392-441 kPa {4.0-4.5 kgf/cm2, 57-63 psi}

8. Install the needle bearing using the SST as shown in the figure.

Distance A

  A: 0-0.5 mm {0-0.02 in}