Direct Clutch

DIRECT CLUTCH

Components





Direct Clutch Disassembly
1. CHECK PACK CLEARANCE OF DIRECT CLUTCH





a) Place the direct clutch assembly onto the O/D support assembly.





b) Using SST and a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (186 - 206 kPa, 1.9 - 2.1 kg-cm2, 27 - 30 psi).
SST 09350-30020 (09350-06120)

Pack clearance: 0.50 - 0.80 mm (0.0197 - 0.0315 inch)

If the values are non-standard inspect the discs.

2. REMOVE FLANGE, PLATES AND DISCS





a) Using a screwdriver, remove the snap ring from the direct clutch drum.





b) Remove the flange, 5 plates and 5 discs.

3. REMOVE PISTON RETURN SPRING





a) Place SST on the spring retainer and compress the return spring with a shop press.
SST 09350-30020 (09350-07040)
b) Using SST, remove the snap ring.
SST 09350-30020 (09350-07070)





c) Remove the piston return spring.

4. REMOVE DIRECT CLUTCH PISTON
a) Place the direct clutch drum onto the O/D support.





b) Hold the direct clutch piston and apply compressed air to the O/D support to remove the direct clutch piston.

HINT: Make sure the direct clutch piston is square in the drum before applying compressed air.

c) Remove the direct clutch piston.





d) Using a small screwdriver, remove the 2 0-rings from the piston.

Direct Clutch Inspection





1. CHECK DIRECT CLUTCH PISTON RETURN SPRING
Check the spring free length together with the spring seat.

Standard free length: 23.25 mm (0.9154 inch)

2. CHECK 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. INSPECT DISC, PLATE AND FLANGE
Check to see if the sliding surface 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 are defaced, replace all discs.
^ Before assembling now discs, soak them in ATF for at least 15 minutes.





4. CHECK DIRECT CLUTCH BUSHING
Using a dial indicator, measure the inside diameter of the clutch drum bushing.

Maximum inside diameter: 53.97 mm (2.1248 inch)

If the inside diameter is greater than the maximum, replace the clutch drum.

Direct Clutch Assembly
1. INSTALL DIRECT CLUTCH PISTON TO DIRECT CLUTCH DRUM





a) Coat new 0-rings With ATF and install them on the direct clutch piston.





b) Being careful not to damage the 0-rings, press in the direct clutch piston into the clutch drum with both hands.

2. INSTALL PISTON RETURN SPRING





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





c) Using SST, install the snap ring.
SST 09350 - 30020 (09350 - 07070)
Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

3. INSTALL PLATES, DISCS AND FLANGE





a) Install the plates and discs.
Install in order: P = Plate D = Disk
P-D-P-D-P-D-P-D-P-D

b) Install the flange, the flat end facing downward.





c) Using a screwdriver, install the snap ring. Be sure the end gap of the snap ring is not aligned with the cutout portion of the direct clutch drum.

4. CHECK PISTON STROKE OF DIRECT CLUTCH





a) Place the direct clutch assembly onto the O/D support assembly.





b) Using SST and a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (186 - 206 kPa, 1.9 - 2.1 kg-cm2, 27 - 30 psi).
SST 09350-30020 (09350-06120)

Pack clearance: 0.50 - 0.80 mm (0.0197 - 0.0315 inch)

If the pack clearance is less than the limit, parts may have been assembled incorrectly, so check and reassemble again.
If the pack clearance is non-standard, select another flange.





HINT: There are 9 different flange thicknesses.