Disassembly

U241E AUTOMATIC TRANSAXLE: DIRECT CLUTCH: DISASSEMBLY

1. INSPECT PACK CLEARANCE OF DIRECT CLUTCH

(a) Install the direct clutch and needle roller bearing on the transaxle rear cover.





(b) Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

Standard pack clearance:

0.652 to 0.872 mm (0.0257 to 0.0343 in.)

If the pack clearance is not as specified, inspect the discs, plates and flange.

2. REMOVE DIRECT MULTIPLE DISC CLUTCH DISC

(a) Using a screwdriver, pry the snap ring out from the direct clutch drum.





(b) Remove the flange, 3 discs and 3 plates from the direct clutch drum.





3. REMOVE DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Place SST on the clutch balancer and compress the spring with a press.





SST : 09387-00020

(b) Using a snap ring expander, remove the snap ring from the direct clutch drum.

NOTICE:
* Stop the press when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove.
* This prevents the spring sheet from being deformed.
* Do not expand the snap ring excessively.

(c) Remove the clutch balancer from the direct clutch drum.





(d) Remove the piston return spring from the direct clutch drum.





(e) Install the direct clutch drum on the transaxle rear cover.





(f) Holding the direct clutch piston with your hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the direct clutch piston.

NOTICE:
* Applying the air may cause the piston to jump out. When removing the piston, hold it using a piece of cloth.
* Do not splash ATF with the compressed air.