Part 2
AT Main Case Continued
4. Install spring retainer to high clutch piston.
5. Install ST to high clutch piston.
ST 498437000 HIGH CLUTCH PISTON GUIDE
6. Avoid folding the high clutch piston seal, when installing the cover to high clutch piston.
7. Using ST1 and ST2, install snap ring.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 498437000 HIGH CLUTCH PISTON GUIDE
8. Install the thickest driven plate to piston side, and then install the driven plate, drive plate, retaining plate to high clutch drum.
9. Install snap ring to high clutch drum.
10. Apply compressed air intermittently to check for operation.
11. Measure the clearance between the retaining plate and snap ring (High clutch). At this time, do not press down retaining plate.
Standard value: 0.8 - 1.1 mm (0.031 - 0.043 inch)
Allowable limit: 1.5 mm (0.059 inch)
If specified tolerance limits are exceeded, select a suitable high clutch retaining plate. If the clearance is above the limit, replace the drive plate with new one and adjust so that the clearance becomes within the specified value.
12. Install driven plate, drive plate, retaining plate and snap ring.
13. Apply compressed air intermittently to check for operation.
14. Measure the clearance between the retaining plate and snap ring (Reverse clutch). At this time, do not press down retaining plate.
Standard value: 0.5 - 0.8 mm (0.020 - 0.031 inch)
Allowable limit: 1.2 mm (0.047 inch)
If specified tolerance limits are exceeded, select a suitable reverse clutch retaining plate.
If the clearance is above the limit, replace the retaining plate with new one, so that the clearance becomes within the specified value.
TURBO MODEL
1. Install the seal ring and lip seal to the high clutch piston and reverse clutch piston.
2. Install the high clutch piston to reverse clutch piston.
3. Install the reverse clutch piston to high clutch drum. Align the groove on reverse clutch piston with the groove on high clutch drum during installation.
4. Install the spring retainer to high clutch piston.
5. Install the ST to high clutch piston.
ST 498437000 HIGH CLUTCH PISTON GUIDE
6. Install the cover to high clutch piston without folding the high clutch piston seal.
7. Install the snap ring using ST1 and ST2.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 498437000 HIGH CLUTCH PISTON GUIDE
8. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
9. Set the micro gauge to clutch, and read its scale.
NOTE: The value, which is read in the gauge at this time, is zero point.
10. Scale and record the weight Z of a flat board which will be put on plates.
NOTE:
^ Use a stiff flat board which does not bend against load.
^ Use a flat board of its weight less than 250 N (25.5 kgs, 56.2 lb).
11. Put the flat board on retaining orate.
12. Using the following formula, calculate N indicated on the push/pull gauge.
N = 250 N (25.5 kgs, 56.2 lb) - Z
N: Value indicated on push/pull gauge
250 N (25.5 kgs, 56.2 lbs.): Load applied to clutch plate
Z: Flat board weight
13. Press the center of retaining plate applying force of N with push/pull gauge, and then measure and record the height A. Make more than three measurements at even distance and take the average value.
NOTE: If three points, measure the height every 120°. If four points, measure the height every 90°.
14. Install the thickest driven plate to piston side, and then install the driven plate, drive plate, retaining plate to high clutch drum.
15. Install the snap ring to high clutch drum.
16. Apply compressed air intermittently to check for operation.
17. Measure and record the clearance B between the retaining plate and snap ring. (High clutch) At this time, do not press down the retaining plate.
18. Piston stroke calculation
Select the retaining plate within the specification by calculating with A and B dimensions which have been recorded before. If the calculated value exceeds the usage limit, replace the drive plate with a new one and adjust it within the specification.
T = A + B
T: Piston stroke
A: Collapse amount of drive plate
B: Clearance between retaining plate and snap ring
Initial standard: 2.0 - 2.3 mm (0.079 - 0.091 inch)
Limit thickness: 2.6 mm (0.102 inch)
19. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
20. Set the micro gauge to clutch, and read its scale.
NOTE: The value, which is read in the gauge at this time, is zero point.
21. Scale and record the weight Z of a flat board which will be put on plates.
NOTE:
^ Use a stiff flat board which does not bend against load.
^ Use a flat board of its weight less than 150 N (15.3 kgs, 33.7 lb).
22. Put the flat board on retaining plate.
23. Using the following formula, calculate N indicated on the push/pull gauge.
N = 150 N (15.3 kgs, 33.7 lb) - Z
N: Value indicated on push/pull gauge
150 N (15.3 kgs, 33.7 lbs.): Load applied to clutch plate
Z: Flat board weight
24. Press the center of retaining plate applying force of N with push/pull gauge, and then measure and record the height A. Make more than three measurements at even distance and take the average value.
NOTE: If three points, measure the height every 120°. If four points, measure the height every 90°.
25. Install the driven plate, drive plate, retaining plate and snap ring.
26. Apply compressed air intermittently to check for operation.
27. Measure and record the clearance B between the retaining plate and snap ring. (Reverse clutch) At this time, do not press down the retaining plate.
28. Piston stroke calculation
Select the retaining plate within the specification by calculating with A and B dimensions which have been recorded before. If the calculated value exceeds the usage limit, replace the drive plate with a new one and adjust it within the specification.
T = A + B
T: Piston stroke
A: Collapse amount of drive plate
B: Clearance between retaining plate and snap ring
Initial standard: 1.1 - 1.4 mm (0.043 - 0.055 inch)
Limit thickness: 1.6 mm (0.063 inch)
PLANETARY GEAR, LOW CLUTCH
1. Install new D-ring to low clutch piston.
2. Fit the low clutch piston to the low clutch drum.
3. Install spring retainer to low clutch piston.
4. Install ST to low clutch drum.
ST 498437100 LOW CLUTCH PISTON GUIDE
5. Set the cover on the piston with a press using ST1 and ST2, and attach the snap ring. At this time, be careful not to fold cover seal during installation.
ST1 498627100 SEAT
ST2 398673600 COMPRESSOR
ST3 498437100 LOW CLUTCH PISTON GUIDE
6. Install the dish plate, driven plates, drive plates, and retaining plate, and secure with the snap ring.
7. Check the low clutch for operation.
1. Remove one-way clutch.
2. Set the one-way clutch inner race, and apply compressed air for checking.
8. Checking low clutch clearance.
1. Place the same thickness of shim on both sides to prevent retaining plate from tilting.
2. Inspect clearance between retaining plate and operation of the low clutch.
Standard value: 0.7 - 1.1 mm (0.028 - 0.043 inch)
Allowable limit: 1.6 mm (0.063 inch)
If the clearance is out of the specified range, select a proper retaining plate so that the standard clearance can be obtained.
If the clearance is above the limit, replace the drive plate with new one, so that the clearance becomes within the specified value.
9. Install washer to rear internal gear.
10. Install rear internal gear.
11. Install thrust needle bearing in the correct direction.
12. Install the washer by aligning protrusion of washer and hole of rear planetary carrier.
13. Install rear planetary carrier to low clutch drum.
14. Install thrust needle bearing in the correct direction.
15. Install the rear sun gear in proper direction.
16. Install the thrust needle bearing in proper direction.
17. Install front planetary carrier to low clutch drum.
18. Install snap ring to low clutch drum.
19. Install the needle bearing, and secure with the snap ring.
20. Install the one-way clutch, one-way clutch inner race and plate, and secure with the snap ring.
21. Set the inner race. Make sure that the forward clutch is free in the clockwise direction and locked in the counterclockwise direction, as viewed from the front of the vehicle.
2-4 BRAKE
1. Install 2-4 brake piston to 2-4 brake piston retainer.
ONE-WAY CLUTCH INNER RACE
1. Using a press and ST, install the needle bearing to the inner race.
ST 398497701 SEAT
2. Apply Vaseline to the groove of the inner race and to the seal ring.
3. Install two seal rings to one-way clutch inner race.
ONE-WAY CLUTCH OUTER RACE
1. Install the needle bearing, and secure with the snap ring.
2. Install the one-way clutch, one-way clutch inner race and plate, and secure with the snap ring.
3. Set the inner race. Make sure that the forward clutch is free in the clockwise direction and locked in the counterclockwise direction, as viewed from the front of the vehicle.
INSPECTION
HIGH CLUTCH AND REVERSE CLUTCH
Inspect the following items.
^ Drive plate facing for wear and damage
^ Snap ring for wear, return spring for setting and breakage, and snap ring retainer for deformation
^ Lip seal and D-ring for damage
^ Piston and drum check ball for operation
^ Adjust total end play.
PLANETARY GEAR AND LOW CLUTCH
Inspect the following items.
^ Drive plate facing for wear and damage
^ Snap ring for wear, return spring for breakage or setting, and spring retainer for deformation
^ Lip seal and D-ring for damage
^ Piston check ball for operation
^ Measure the total end play and adjust to within specifications.
2-4 BRAKE
Inspect the following items.
^ Drive plate facing for wear and damage
^ Snap ring for wear and spring retainer for deformation
^ Lip seal and D-ring for damage
^ Measure the total end play and adjust to within specifications.
ONE-WAY CLUTCH
^ Make sure the snap ring is not worn and the seal rings are not damaged.
^ Measure the total end play and adjust to within specifications.
LOW AND REVERSE BRAKE
Check for the following.
^ Drive plate facing for wear or damage
^ Snap ring for wear and spring retainer for deformation