A/T Clutch Clearance Inspection

A/T Clutch Clearance Inspection

Special Tools Required

- Clutch compressor attachment 07ZAE-PRP0100
1. Inspect the clutch piston, discs, plates, and end-plate for wear and damage, A/T Clutch Inspection and inspect the clutch wave-plate phase difference, A/T Clutch Wave-Plate Phase Difference Inspection if necessary.

2. Install the 1st-hold clutch piston in the 1st clutch piston, and install 1st/1st-hold clutch piston (A) in the 1st/1st-hold clutch drum (B). Do not install the O-rings on the clutch pistons during inspection.






3. Install the 1st-hold clutch flat-plate (A), and alternately install the clutch discs (B) (3) and clutch wave-plates (C) (2) starting with the disc, then install 1st-hold clutch plate B (D) with the flat side down on the top disc.






4. Measure the clearance between the 1st-hold clutch plate B and top disc with a feeler gauge (A) while pressing the 1st-hold clutch plate B down. Take measurements in at least three places, and use the average as the actual clearance.





5. If the clearance is out of the standard, replace the 1st-hold clutch plates and discs as a set, and recheck.






6. Install the disc spring (A) on 1st-hold clutch plate B in the direction shown. Starting with the 1st clutch wave-plate, alternately install the wave-plates (B) (5) and discs (C) (5) in the 1st clutch drum (D), then install the clutch end-plate (E) with the flat side down on the top disc.






7. Install the clutch pistons in the 2nd, 3rd, 4th, and 5th clutch drums. Do not install the O-rings on the clutch pistons during inspection.






8. Starting with the 2nd clutch flat-plate, alternately install the flat-plates (A) (4) and discs (B) (4) in the 2nd clutch drum (C), and alternately install the wave-plates (D) (3) and discs (B) (3). Install the clutch end-plate (E) with the flat side down on the top disc.






9. Starting with the 3rd clutch flat-plate, alternately install the flat-plates (A) (3) and discs (B) (3) in the 3rd clutch drum (C), and alternately install the wave-plates (D) (3) and discs (B) (3). Install the clutch end-plate (E) with the flat side down on the top disc.






10. Install the disc spring (A) in the 4th clutch drum (B) in the direction shown. Starting with the 4th clutch flat-plate, alternately install the flat-plates (C) (3) and discs (D) (3), and alternately install the wave-plates (E) (2) and discs (D) (2). Install the clutch end-plate (F) with the flat side down on the top disc.






11. Install the disc spring (A) in the 5th clutch drum (B) in the direction shown. Starting with the 5th clutch flat-plate, alternately install the flat-plates (C) (3) and discs (D) (3), and alternately install the wave-plates (E) (2) and discs (D) (2). Install the clutch end-plate (F) with the flat side down on the top disc.






12. Install the snap ring with a screwdriver to secure the clutch end-plate.






13. Set a dial indicator (A) on the clutch end-plate (B).

14. Zero the dial indicator with the clutch end-plate lifted up to the snap ring (C).






15. Release the clutch end-plate to lower the clutch end-plate, then put the clutch compressor attachment on the end-plate (A).

16. Press the clutch compressor attachment down with 150-160 N (15-16 kgf, 33-35 lbf) (B) using a force gauge, and read the dial indicator (C).

17. The dial indicator reads the clearance (D) between the clutch end-plate and top disc (E). Take measurements in at least three places, and use the average as the actual clearance.










18. If the clearance is out of the service limit, select a new clutch end-plate from the following table.

1ST CLUTCH END PLATES





2ND CLUTCH END PLATES





3RD CLUTCH END PLATES





4TH and 5TH CLUTCH END PLATES





19. Install the new clutch end-plate, and recheck the clearance. If the thickest clutch end-plate is installed, but the clearance is still over the service limit, replace the clutch discs and plates.