Direct Clutch

DIRECT CLUTCH





Components

Direct Clutch Disassembly
1. CHECK PISTON STROKE OF DIRECT CLUTCH





a. Install the direct clutch on the oil pump.





b. Set a dial indicator and measuring terminal Special Service Tool (SST) together, measure the direct clutch piston stroke while applying and releasing compressed air (392 - 785 kPa, 4 - 8 kgf/cm2, 57 - 114 psi).
SST 09350-32014 (09351-32190)

Piston stroke: 1.11 - 1.44 mm (0.0437 - 0.0567 inch)

If the piston stroke is greater than the maximum, inspect each component.





2. REMOVE SNAP RING FROM CLUTCH DRUM
3. REMOVE FLANGE, DISCS AND PLATES





4. REMOVE PISTON RETURN SPRING
a. Place SST on the spring retainer and compress the springs with a shop press.
SST 09350-32014 (09351-32070)
b. Remove the snap ring with the snap ring pliers.





c. Remove the piston return spring.





5. REMOVE CLUTCH PISTON
a. Install the direct clutch onto the oil pump.
b. Apply compressed air to the oil pump to remove the piston. (if the piston does not come out completely, use needle-nose pliers to remove it).
c. Remove the direct clutch from the oil pump.





d. Remove the 2 O-rings from the piston.

Direct Clutch Inspection





1. INSPECT 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.





2. INSPECT DISCS, PLATES AND FLANGE
Check if the sliding surfaces of the discs, plates 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 new discs, soak them in Automatic Transmission Fluid (ATF) for at least 15 minutes.





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

Maximum inside diameter: 47.07 mm (1.8531 inch)

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

Direct Clutch Assembly





1. INSTALL CLUTCH PISTON IN DIRECT CLUTCH DRUM
a. Install new O-rings to the piston. Coat the O-rings with Automatic Transmission Fluid (ATF).
b. Being careful not to damage the O-rings, press the piston into the drum with the cup side up.





2. INSTALL PISTON RETURN SPRING
a. Place the return spring and snap ring onto the piston.
b. Place Special Service Tools (SST) on the spring retainer, and compress the return spring with a shop press.
SST 09350-32014 (09351 -32070)
c. Install the snap ring with the snap ring pliers. Be sure the end gap of snap ring is not aligned with the spring retainer claw.





3. INSTALL PLATES, DISCS AND FLANGE
a. Install plates and discs.
Install in order: P=Plate D=Disc
P - D - P - D - P - D
b. Install the flange with the flat end facing downward.





4. INSTALL SNAP RING
Check that the end gap of the snap ring is not aligned with one of the cutouts.
5. RECHECK PISTON STROKE OF DIRECT CLUTCH





a. Install the direct clutch on the oil pump.





b. Set a dial indicator and measuring terminal (SST) together, measure the direct clutch piston stroke while applying and releasing compressed air (392 - 785 kPa, 4 - 8 kgf/cm2, 57 - 114 psi).
SST 09350-32014 (09351-32190)

Piston stroke: 1.11 - 1.44 mm (0.0437 - 0.0567 inch)

If the piston stroke is non-standard, select another flange.

HINT: There are 2 different flange thickness.

Flange thickness:
2.60 mm (0.1024 inch)
3.00 mm (0.1181 inch)