Overdrive Direct Clutch

DISASSEMBLY

1. CHECK OPERATION OF ONE-WAY CLUTCH
Hold the O/D direct clutch drum and turn the input shaft.
Check that the input shaft must be able to turn freely clockwise and locks counterclockwise.

2. REMOVE O/D DIRECT CLUTCH ASSEMBLY FROM O/D PLANETARY GEAR
3. CHECK PISTON STROKE OF O/D DIRECT CLUTCH

a. Place the oil pump onto the torque converter clutch, and then place the O/D direct clutch assembly onto the oil pump.

a. Using a screwdriver, remove the snap ring from the O/D direct clutch drum.

b. Remove the flange.

c. Remove the 2 plates and discs.

5. REMOVE PISTON RETURN SPRING
a. Place SST on the spring retainer and compress the return spring with a press.
SST 09350-30020 (09350-07040)

NOTICE:
- Stop the press when the spring sheet is lowered to the place 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove, preventing the spring sheet from being deformed.
- Do not expand the snap ring excessively.

b. Using snap ring pliers, remove the snap ring.
c. Remove the piston return spring.

6. REMOVE O/D DIRECT CLUTCH PISTON
a. Place the oil pump onto the torque converter clutch and then place the O/D direct clutch onto the oil pump.
b. Hold the O/D direct clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil pump to remove the O/D direct clutch piston.
c. Remove the O/D direct clutch piston.

HINT: If the piston is at an angle and cannot be removed, press down on the side jutting out and again apply compressed air, or wind vinyl tape around the piston end and remove it with needle nose pliers.

d. Remove the 2 O-rings from the piston.
7. REMOVE RING GEAR FLANGE

a. Using a screwdriver, remove the snap ring.

b. Remove the ring gear flange.
8. REMOVE RETAINING PLATE

a. Using a screwdriver, remove the snap ring.

b. Remove the retaining plate.

9. REMOVE O/D ONE-WAY CLUTCH WITH OUTER RACE

10. REMOVE O/D ONE-WAY CLUTCH FROM OUTER RACE
a. Remove the O/D one-way clutch from the outer race.
b. Remove the 2 retainers from the O/D one-way clutch.

11. REMOVE THRUST WASHER

INSPECTION

1. INSPECT DISC, PLATE AND FLANGE
Check to see if the sliding surfaces of the disc, plate and flange are worn or burnt. If necessary, replace them.

HINT:
- If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers is defaced, replace discs.
- Before assembling new discs, soak them in ATF for at least 15 minutes.

2. CHECK O/D DIRECT CLUTCH PISTON
a. Check that the check ball is free by shaking the piston.
b. Check that the valve does not leak by applying low-pressure compressed air.

3. CHECK O/D DIRECT CLUTCH DRUM BUSHING
Using a dial indicator, measure the inside diameter of the clutch drum bushings.
Maximum Inside diameter: 27.11 mm (1.0673 inch)
If the inside diameter is greater than the maximum, replace the clutch drum.

4. CHECK O/D PLANETARY GEAR BUSHING
Using a dial indicator, measure the inside diameter of the planetary gear bushing.
Maximum Inside diameter: 11.27 mm (0.4437 inch)
If the inside diameter is greater than the maximum, replace the planetary gear.

5. MEASURE PLANETARY PINION GEAR THRUST CLEARANCE
Using a feeler gauge, measure the planetary pinion gear thrust clearance.
Standard clearance: 0.20 - 0.60 mm (0.0079 - 0.0236 inch)
Maximum clearance: 1.00 mm (0.0394 inch)
If the clearance is greater than the maximum, replace the planetary gear assembly.

6. CHECK O/D DIRECT CLUTCH RETURN SPRING
Measure the free length of the spring together with the spring seat.
Standard free length: 15.8 mm (0.622 inch)

REASSEMBLY

1. INSTALL THRUST WASHER TO O/D PLANETARY GEAR
Install the thrust washer to the O/D planetary gear with the groove side facing upward.
2. INSTALL O/D ONE-WAY CLUTCH
a. Install the 2 retainers to the O/D one-way clutch.

b. Install the O/D one-way clutch into the O/D one-way clutch outer race with the flange side of the O/D one-way clutch facing upward.

c. Install the O/D one-way clutch with the outer race to the O/D planetary gear.
3. INSTALL RETAINING PLATE

a. Install the retaining plate.

b. Using a screwdriver, install the snap ring.
4. INSTALL RING GEAR FLANGE TO O/D PLANETARY GEAR

a. Install the ring gear flange.

b. Using a screwdriver, install the snap ring.

5. INSTALL O/D DIRECT CLUTCH PISTON
a. Coat new O-rings with ATF and install them on the O/D direct clutch piston.
b. Being careful not to damage the O-rings, press in the direct clutch piston into the clutch drum with both hands.
6. INSTALL PISTON RETURN SPRING

a. Install the piston return spring to the piston.

b. Place SST on the spring retainer, and compress the return spring with a press.
SST 09350-30020 (09350-07040)

NOTICE:
- Stop the press when the spring sheet is lowered to the place 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove, preventing the spring sheet from being deformed.
- Do not expand the snap ring excessively.

c. Using a screwdriver, install the snap ring. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

7. INSTALL PLATE, DISC AND FLANGE

a. Install the 2 plates and discs.
Install In order: P = Plate D = Disc
P - D - P - D

b. Install the flange with the flat end facing downward.

c. Using a screwdriver, install the snap ring.
8. CHECK PISTON STROKE OF O/D DIRECT CLUTCH

a. Place the oil pump onto the torque converter clutch, and then place the O/D direct clutch assembly onto the oil pump.

b. Using SST and a dial indicator, measure the O/D direct clutch piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
SST 09350-30020 (09350-06120)
Piston stroke: 1.77 - 2.07 mm (0.0697 - 0.0815 inch)
If the piston stroke is less than the limit, parts may have been assembled incorrectly, check and reassemble again.
If the piston stroke is non-standard, select another flange.

HINT: There are 6 different thicknesses for the flange.

Flange thickness:

9. INSTALL O/D DIRECT CLUTCH ASSEMBLY
a. Align the flukes of the discs in the direct clutch.
b. Install the direct clutch assembly onto the O/D planetary gear.

10. CHECK OPERATION OF ONE-WAY CLUTCH
Hold the O/D direct clutch drum and turn the input shaft. Check that the input shaft must be able to turn freely clockwise and locks counterclockwise.