DIRECT CLUTCH DISASSEMBLY


  1. INSPECT PACK CLEARANCE OF DIRECT CLUTCH


    1. A01BBQ8

      Place the direct clutch assembly onto the O/D support assembly.

    2. A01BH15E01

      Using SST and a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (186 to 206 kPa, 1.9 to 2.1 kgf/cm2, 27 to 30 psi).

      Pack Clearance
      0.40 to 0.70 mm (0.016 to 0.028 in.)

      If the pack clearance is outside the standard inspect the discs.

  2. REMOVE DIRECT CLUTCH FLANGE


    1. A01BG4R

      Using a screwdriver, remove the snap ring from the direct clutch drum.

    2. Remove the flange, the 4 plates and the 4 discs.

  3. INSPECT DIRECT CLUTCH FLANGE


    1. A01BAWOE02

      Check to see if the sliding surface of the disc, the plate and the flange are worn or burnt. If necessary, replace them.

      Tech Tips


      • If the lining of the disc is peeled off or discolored, or even if only a part of the printed numbers is corroded, replace all discs.

      • Before assembling new discs, soak them in ATF for at least 15 minutes.

  4. REMOVE DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A01BDACE03

      Place SST on the piston return spring and compress.

      SST
      09350-30020   ( 09350-07040 )

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )
    3. A01BF3F

      Remove the return spring.

  5. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A01BEME

      Measure the free length of the spring together with the spring seat.

      Standard free length
      21.32 mm (0.839 in.)

  6. REMOVE DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A01BG0P

      Place the direct clutch drum onto the O/D support.

    2. Hold the direct clutch piston, and apply compressed air (196 kPa, 2.0 kgf/cm2, 28.5 psi) to the O/D support to remove the direct clutch piston.

      Tech Tips

      Make sure the direct clutch piston is at a right angle to the drum before applying compressed air.

    3. A01BESOE02

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

  7. INSPECT DIRECT CLUTCH PISTON SUB-ASSEMBLY


    1. A01BDNI

      Check that the check ball is free by shaking the piston.

    2. Check that the valve does not have leaks by applying low-pressure compressed air.

  8. INSPECT DIRECT CLUTCH DRUM SUB-ASSEMBLY


    1. A01BC2Y

      Using a deal indicator, measure the inside diameter of the clutch drum bushing.

      Maximum inside diameter
      53.97 mm (2.1248 in.)

      If the inside diameter is greater than the maximum, replace the clutch drum.