Direct Clutch

DISASSEMBLY

1. REMOVE DIRECT CLUTCH DRUM FROM FORWARD CLUTCH

2. REMOVE CLUTCH DRUM THRUST WASHER FROM DIRECT CLUTCH
3. CHECK PISTON STROKE OF DIRECT CLUTCH

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

4. REMOVE FLANGE, PLATE AND DISC
a. Using a screwdriver, remove the snap ring from the direct clutch drum.
b. Remove the flange, plates and discs.

5. REMOVE PISTON RETURN SPRING
a. Place SST on the spring retainer and compress the piston 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 deforming. Do not expand the snap ring excessively.

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

6. REMOVE DIRECT CLUTCH PISTON
a. Place the direct clutch drum onto the O/D support.
b. Hold the direct clutch piston, apply compressed air to the O/D support to remove the direct clutch piston.
c. Remove the 2 O-rings from the piston.

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 all discs.
- Before assembling new discs, soak them in ATF for at least 15 minutes.

2. CHECK DIRECT CLUTCH RETURN SPRING
Measure the free length of the spring together with the spring seat.
Standard free length: 23.25 mm (0.915 inch)

3. 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.

4. CHECK DIRECT CLUTCH DRUM BUSHING
Using a dial indicator, measure the inside diameter of the clutch drum bushing.
Maximum inside diameter: 53.99 mm (2.1256 inch)
If the inside diameter is greater than the maximum, replace the clutch drum.

REASSEMBLY
INSTALL DIRECT CLUTCH PISTON TO DIRECT CLUTCH DRUM
a. Coat 2 new O-rings with ATF and install them on the direct clutch piston.

b. Being careful not to damage the O-rings, press 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 spring 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 snap ring pliers, install the snap ring. Make sure the end gap of the snap ring is not aligned with the spring retainer.
3. INSTALL PLATE, DISC AND FLANGE

a. Install the 4 plates and discs.
Install in order: P = Plate D = Disc
P - D - P - D - P - D - P - D

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

c. Using a screwdriver, install the snap ring. Make 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 piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
SST 09350-30020 (09350-06120)
Piston stroke: 1.03 - 1.33 mm (0.0405 - 0.0524 inch)
If the piston stroke is less than the limit, parts may have been assembled incorrectly, so check and reassemble again.
If the piston stroke is non-standard, select another flange.

HINT: There are 8 different thicknesses for the flange.

Flange thickness

5. INSTALL CLUTCH DRUM THRUST WASHER
Coat the thrust washer with petroleum jelly and install it onto the direct clutch.
6. INSTALL DIRECT CLUTCH TO FORWARD CLUTCH

a. Align the flukes of the discs in the direct clutch.
b. Install the direct clutch onto the forward clutch.

c. Check that the distance from the direct clutch end to the forward clutch end is 71.2 mm (2.803 inch).
If the distance is less than the above value, parts may have been assembled incorrectly, check and reassemble again.