Direct Clutch

PRELIMINARY CHECK





Check direct clutch clearance before disassembly. For checking clearance, measure height between snap ring and clutch flange by using vernier as shown in figure. If height is within specification, it means that clutch clearance is within specification. If height is out of specification, replace clutch discs or plates with new ones.
Height "a": 2.49 - 3.06 mm (0.098 - 0.120 inch)






REMOVAL
1. Remove clutch plate snap ring.





2. Remove clutch flange, discs and plates.





3. Remove spring seat snap ring. Compress piston return springs by using special tool and then remove snap ring.

CAUTION: Do not compress spring seat too much. Excessive compression may cause to spring seat to become distorted.

Special Tool
(A): 09926 - 98310





4. Remove spring seat and return spring assembly.
5. Remove direct clutch piston. Blow compressed air through drum oil hole to remove piston. If piston does not pop out, take out piston with long nose pliers.





6. Remove inner seal from drum.
7. Remove outer seal from piston.

INSPECTION





1. Check valve (steel ball) for free movement in piston.
2. Check valve for leakage by using low pressure air. If found faulty, replace piston.

INSTALLATION





1. Install inner seal (O-ring).
Apply transmission fluid to inner seal and fit it in drum.
Use new inner seal.
2. Install outer seal (O-ring).
Apply transmission fluid to outer seal and fit it to piston.
Use new outer seal.





3. Install piston into drum.
Be careful so that seals (O-rings) do not get twisted or caught.





4. Install clutch return spring assembly.
5. Install spring seat.
6. Install snap ring.
Compress return springs and install spring seat snap ring in groove. Place special tool (clutch spring compressor) on spring seat and compress springs with press, and then, install snap ring using a screwdriver.

CAUTION:
- Check to make sure that snap ring is securely fitted in 4 projections A of spring seat.
- Do not compress return spring more than necessary.

Special Tool
(A): 09926 - 98310





7. Install discs, plates and flange in following order.
(1) Plate -> (2) Disc -> (3) Plate -> (4) Plate -> (5) Disc -> (6) Flange

NOTE: If new clutch discs are installed, soak them in automatic transmission fluid for 2 hours or more before assembly.

8. Install clutch plate snap ring.





9. After installing clutch plate snap ring, measure height between snap ring and clutch flange as previously outlined.
If height is out of specification even when new clutch discs and plates are installed, install flange of different thickness. Following 2 types of clutch flanges are available as spare parts.





Height "a": 2.49 - 3.06 mm (0.098 - 0.120 inch)





10. Check piston for movement by blowing air through oil hole in drum.

CAUTION: Apply only low pressure air for checking movement. Excessive air pressure may cause damage to spring seat.