Forward Clutch Assembly

Forward Clutch Assembly

REMOVAL

1) Remove the transmission assembly from the vehicle.
2) Remove the air breather hose.
3) Remove the control valve body.
4) Remove the transmission harness.
5) Remove the turbine speed sensor.
6) Remove the secondary speed sensor.
7) Remove the primary speed sensor.
8) Remove the inhibitor switch.
9) Remove the extension case.
10) Remove the transfer clutch assembly.
11) Remove the transfer driven gear assembly.
12) Remove the parking pawl.
13) Remove the reduction driven gear assembly.
14) Remove the oil pan and oil strainer.
15) Remove the transmission control device.
16) Remove the transmission case.
17) Remove the reduction drive gear.
18) Remove the primary pulley, secondary pulley and variator chain.
19) Remove the reverse brake assembly.
20) Remove the internal gear.





21) Remove the thrust bearing.





22) Remove the planetary carrier.





23) Remove the thrust bearing and sun gear.





24) Remove the forward clutch assembly.





25) Remove the thrust bearing and seal ring.





INSTALLATION

1) Install the thrust bearing to the converter case.

NOTE:
Face the temper color surface to the converter case side.





2) Install the seal ring to the input shaft.

NOTE:
^ Use a new seal ring.
^ When installing the seal ring, do not expand the seal ring too much.
^ Apply CVTF to the seal rings.





3) Install the forward clutch assembly to the converter case.





4) Install the sun gear.

NOTE:
Face the end face of the sun gear to the reverse brake side as shown in the figure.





5) Install the thrust bearing to the sun gear.

NOTE:
Face the temper color surface to the reverse brake side.





6) Install the planetary carrier.





7) Install the thrust bearing.

NOTE:
Face the temper color surface to the reverse brake side.





8) Install the internal gear.





9) Install the thrust bearing to the internal gear.

NOTE:
Face the temper color surface to the reverse brake side.





10) Select a washer.
11) Install the reverse brake assembly.
12) Install the primary pulley, secondary pulley and variator chain.
13) Install the reduction drive gear.
14) Install the transmission case.
15) Install the transmission control device.
16) Install the oil strainer and oil pan.
17) Install the reduction driven gear assembly.
18) Install the transfer driven gear assembly.
19) Install the transfer clutch assembly.
20) Install the parking pawl.
21) Install the extension case.
22) Install the inhibitor switch.
23) Install the secondary speed sensor.
24) Install the primary speed sensor.
25) Install the turbine speed sensor.
26) Install the transmission harness.
27) Install the control valve body.
28) Install the air breather hose.
29) Install the transmission assembly to the vehicle.

DISASSEMBLY

FORWARD CLUTCH ASSEMBLY

1) Remove the snap ring.
2) Remove the retaining plate, drive plate, driven plate and dish plate.





3) Compress the return spring using the ST to remove the snap ring.
ST1 18762AA010 COMPRESSOR SPECIAL TOOL
ST2 398673600 COMPRESSOR





4) Remove the chamber COMPL and snap ring.





5) Remove the return spring.





6) Remove the forward clutch piston by blowing compressed air intermittently from the forward clutch carrier hole.





PLANETARY CARRIER ASSY

NOTE:
Disassemble the balance oil guide only.

1) Remove the snap ring.





2) Remove the balance oil guide.

INTERNAL GEAR

1) Remove the snap ring.





2) Remove the thrust gear plate.





ASSEMBLY

FORWARD CLUTCH ASSEMBLY

1) Install the forward clutch piston to forward clutch drum.

NOTE:
^ Apply CVTF to the seal of forward clutch piston.
^ Insert it all the way to the end.





2) Install the return spring.





3) Install the chamber COMPL.

NOTE:
Apply CVTF to the sealing area of chamber COMPL.





4) Compress the return spring using the ST to install the snap ring.
ST1 18762AA010 COMPRESSOR SPECIAL TOOL
ST2 398673600 COMPRESSOR





5) Check the operation of forward clutch piston by blowing compressed air intermittently from forward clutch carrier hole.





6) Place the driven plate, drive plate and retaining plate neatly in this order on surface table.
7) Set the dial gauge to retaining plate, and read its scale.

NOTE:
The value, which is read in the gauge at this time, is zero point.

8) Scale and record the weight "Z" of a flat board which will be put on retaining plate.

NOTE:
^ The value, which is read in the gauge at this time, is zero point.
^ Use a flat board weighing less than 52 N (5.3 kgf, 11.7 lb).

9) Put the flat board on retaining plate.





10) Using the following formula, read the push/pull gauge and calculate "N".
N = 52 N (5.3 kgf, 11.7 lb) - Z
52 N (5.3 kgf, 11.7 lb) : Load applied to clutch plate
Z: Flat board weight

11) Press the center of retaining plate by applying a force of "N" using push/pull gauge, and then measure and record the compression amount "A".

NOTE:
Measure at four points with a 90° interval and calculate the average.





12) Install the dish plate, drive plate, driven plate, retaining plate and snap ring to the forward clutch carrier.

NOTE:
Install the dish plate in the correct direction.





13) Measure and record the clearance "B" between the retaining plate and snap ring.





14) Piston stroke calculation
Calculate with A and B dimensions recorded before.
If it exceeds the limit, replace with a new drive plate and adjust within the initial standard value.
S mm (in) = A + B
S: Piston stroke
A: Compression amount of drive plate and dish plate
B: Clearance between retaining plate and snap ring

Initial standard:
1.0 - 1.4 mm (0.040 - 0.055 in)

Limit thickness:
1.6 mm (0.063 in)





PLANETARY CARRIER ASSY

NOTE:
Assemble in the reverse order of disassembly.

INTERNAL GEAR

NOTE:
Assemble in the reverse order of disassembly.

INSPECTION

^ Check the forward clutch drum, internal gear, sun gear and forward clutch piston lip for wear or damage.
^ Inspect the drive plate facing for wear and damage.
^ Check the driven plate for discoloration (burnt color).
^ Check for worn snap ring, fatigue or damaged return spring or deformed spring retainer.
^ Make sure the clearance between retaining plate and internal gear of forward clutch is within the limit. If it exceeds the standard, replace the forward clutch.

ADJUSTMENT

1) Install the thrust bearing to the internal gear.

NOTE:
Face the temper color surface to the reverse brake side.





2) Measure depth "A" from the ST upper face to the washer mounting surface.
ST 499575600 GAUGE





3) Measure the height "B" from the ST upper face to the mating surface of the drive pinion retainer.
ST 499575600 GAUGE





4) Obtain the thickness of washer using the following formula to select the washer.
T (mm) = A - B - (0.35 - 0.70)
[T (in) = A - B - (0.014 - 0.028)]
T: Shim thickness
A: Depth from the ST upper face to the washer mounting surface
B: Height from ST upper face to the drive pinion retainer mating surface
0.35 - 0.70 mm (0.014 - 0.028 in): Clearance