FORWARD CLUTCH (for 1KD-FTV) DISASSEMBLY


  1. FIX FORWARD CLUTCH ASSEMBLY


    1. A01BI6Y

      Place wooden blocks, etc., to prevent the input shaft sub-assembly from touching the work stand, and place the overdrive support sub-assembly on them.

    2. Place the forward clutch assembly onto the overdrive support sub-assembly.

  2. INSPECT PISTON STROKE OF FORWARD CLUTCH


    1. A01BB5TE02

      Using SST and a dial indicator, measure the forward clutch piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

      SST
      09350-30020   ( 09350-06120 )
      Piston stroke
      0.60 to 1.00 mm (0.0236 to 0.0394 in.)

      If the piston stroke is less than the limit, parts may be assembled incorrectly, so inspect and reassemble them if necessary.

      If the piston stroke is outside the standard range, select another flange.

      Tech Tips

      There are 8 different flanges in thickness.

      Flange thickness
      No.

      Thickness

      mm (in.)

      		 No.

      Thickness

      mm (in.)
      90 3.0 (0.118) 94 3.8 (0.150)
      91 3.2 (0.126) 95 4.0 (0.157)
      92 3.4 (0.134) 96 4.2 (0.165)
      93 3.6 (0.142) 97 4.4 (0.173)

  3. REMOVE FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC


    1. A01BD7G

      Using a screwdriver, remove the snap ring from the forward clutch assembly.

      Tech Tips

      Tape up the screwdriver tip before use.

    2. Remove the flange, the 6 plates and the 6 discs.

    3. A01BABT

      Remove the cushion plate.

  4. INSPECT FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC


    1. A01BHRP

      Check if the sliding surface of the disc, the plate and 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.

  5. REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A01BI75E02

      Place SST on the spring retainer, and compress the forward clutch return spring sub-assembly with a press.

      SST
      09350-30020   ( 09350-07040 )

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )
    3. A01BGU1

      Remove the forward clutch return spring sub-assembly.

  6. REMOVE FORWARD CLUTCH PISTON SUB-ASSEMBLY


    1. A01BCYR

      Place the forward clutch assembly onto the overdrive support sub-assembly.

    2. While holding the forward clutch piston sub-assembly apply compressed air (196 kPa, 2.0 kgf/cm2, 28.5 psi) to the overdrive support sub-assembly.

    3. Remove the forward clutch piston sub-assembly.

    4. A01BD5P

      Remove the O-ring.

  7. REMOVE FORWARD CLUTCH PISTON O-RING


    1. A01BFSGE02

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

  8. INSPECT FORWARD CLUTCH PISTON SUB-ASSEMBLY


    1. A01BDNI

      Check that the check ball is moves freely by shaking the piston.

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

  9. REMOVE INPUT SHAFT OIL SEAL RING


    1. A01BFLQ

      Remove the 3 input shaft oil seal rings from the input shaft sub-assembly.

  10. INSPECT INPUT SHAFT SUB-ASSEMBLY


    1. A01BF88

      Using a dial indicator, measure the inside diameter of the input shaft sub-assembly bushing.

      Maximum inside diameter
      24.08 mm (0.9480 in.)

      If the inside diameter is greater than the maximum, replace the input shaft sub-assembly.