Direct Clutch Assembly Assemble

Direct Clutch Assembly Assemble

Tools Required
^ DT 46451 (DW240-020) Brake/Clutch Spring Compressor
^ DT 46453 (DW240-040) Direct Clutch Adapter





Important
Do not expand the ring ends excessively.

1. Install the 2 seal rings (1) to the input shaft.





2. Coat a new O-ring (1) with automatic transmission fluid (ATF) and install the O-ring to the input shaft.





3. Coat a new O-ring (1) with ATF and install the O-ring to the direct clutch piston.





Important
Do not damage the lip seal of direct clutch piston.

4. Coat the direct clutch piston with ATF, and install it to the direct clutch drum.





5. Install the direct clutch return spring.





6. Place the DT 46451 (1) and the DT 46453 (2) on the return spring and compress.

Notice
Refer to Transaxle Case Damage Notice in Service Precautions.

Important
Do not expand the snap ring excessively.

7. Using a snap ring expander, install the snap ring.





Important
Before installing the discs, coat them with ATF.

8. Install the 2 plates (2), 2 discs (3), and the flange (1) in order: 2-3-2-3-1.





9. Using a screwdriver, remove the snap ring.
10. Check that the end gap of the snap ring is not aligned with one of the cutouts.





11. Install the direct clutch on the oil pump.

Notice
Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice in Service Precautions.

12. Using a dial indicator, measure the direct clutch piston stroke while applying and releasing 392 kPa (57 psi) of compressed air.
The piston stroke is 0.4 - 0.8 mm (0.016 - 0.031 inch).
^ If the piston stroke is less than the limit of piston stroke, parts may have been assembled incorrectly, so check and reassemble again.
^ If the stroke is non-standard, select another flange.
^ There are 3 flanges in different thickness.
^ The number 1 flange thickness is 3 mm (0.118 inch).
^ The number 2 flange thickness is 3.2 mm (0.126 inch).
^ The number 3 flange thickness is 3.4 mm (0.134 inch).