Direct Clutch

DISASSEMBLY
1. CHECK PISTON STROKE OF DIRECT CLUTCH
a. Install the direct clutch on the oil pump.





b. Install 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: 0.91 - 1.35 mm (0.0358 - 0.0531 inch)





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





2. REMOVE SNAP RING FROM CLUTCH DRUM
Using a screwdriver, remove the snap ring from the clutch drum.
3. REMOVE FLANGE, 3 DISCS AND 3 PLATES
4. REMOVE PISTON RETURN SPRING





a. Place SST on the spring retainer and compress the springs with a press.
SST 09350-32014 (09351-32070)

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 a snap ring expander, remove the snap ring with 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 (392 - 785 kPa, 4 - 8 kgf/cm2, 57 - 114 psi) 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. Using a screwdriver, remove the 2 O-rings from the piston.

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 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: 48.27 mm (1.9004 inch)
If the inside diameter is greater than the maximum, replace the direct clutch.

REASSEMBLY





1. INSTALL CLUTCH PISTON IN DIRECT CLUTCH DRUM
a. Install 2 new O-rings to the piston. Coat the O-rings with ATF.
b. Being careful not to damage the O-rings, press in 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 SST on the spring retainer, and compress the return spring with a press.
SST 09350-32014 (09351-32070)

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.

c. Using a snap ring expander install the snap ring. Be sure the end gap of snap ring is aligned with the spring retainer claw.





3. INSTALL PLATE, DISC AND FLANGE
a. Install 3 plates and 3 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
a. Using a screwdriver, install the snap ring.
b. 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. Install 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: 0.91 - 1.35 mm (0.0358 - 0.0531 inch)
If the piston stroke in non-standard, select another flange.





HINT: There are 2 different thickness for the flange.

Flange thickness:
2.70 mm (0.1063 inch)
3.00 mm (0.1181 inch)