Forward Clutch

DISASSEMBLY
1. CHECK PISTON STROKE OF FORWARD CLUTCH

Install a dial indicator and measuring terminal Special Service Tool (SST) together, measure the forward 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: 1.79 - 2.21 mm (0.0704 - 0.0870 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, 5 DISCS AND 5 PLATES
4. REMOVE RETURN SPRING

a. Place SST on the return spring 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.

c. Remove the return spring.
5. REMOVE CLUTCH PISTON

a. Apply compressed air (392 - 785 kPa, 4 - 8 kgf/cm2, 57 - 114 psi) into the oil passage to remove the piston.
If the piston does not come out, use needle-nose pliers to remove it.

b. Using a small screwdriver, remove the 2 O-rings from the piston.

6. REMOVE OIL SEAL RING
Remove the 3 oil seal rings from the shaft.

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 DISC, PLATE 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 CLUTCH RETURN SPRING
Using a vernier calipers, measure the free length of the spring together with the spring seal.
Standard free length: 22.58 mm (0.8890 inch)

REASSEMBLY

1. INSTALL OIL SEAL RING
Install the 3 oil seal rings to the shaft.

NOTICE: Do not spread the ring ends more than necessary.

HINT: After installing the oil seal rings, check that they move smoothly.

2. INSTALL CLUTCH PISTON TO CLUTCH DRUM

a. Install 2 new O-rings to the piston.

b. Coat the O-ring with ATF.
c. Press the piston into the drum with the cup side up.

NOTICE: Be careful not to damage the O-rings.

3. 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 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.

c. Using a snap ring expander, install the snap ring. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

4. INSTALL PLATE, DISC AND FLANGE
a. Install the plates and discs.
Install in order:
P = Plate D = Disc
P - D - P - D - P - D - P - D - P - D
b. Install the flange with the flat end facing downward.

5. INSTALL SNAP RING
a. Using a screwdriver, install the snap ring.
b. Check that the end gap of snap ring is not aligned with one of the cutouts.
6. RECHECK PISTON STROKE OF FORWARD CLUTCH

HINT: There are 2 different thicknesses for the flange.

Flange thickness:
2.30 mm (0.0906 inch)
2.70 mm (1.0630 inch)