FORWARD CLUTCH (for 1KD-FTV) REASSEMBLY


  1. INSTALL INPUT SHAFT OIL SEAL RING


    1. A01BAWW

      Coat the 3 input shaft oil seal rings with ATF.

    2. Squeeze the ends of the 3 oil seal rings together, and then install them into the input shaft sub-assembly groove.

      Note

      Do not overspread the ring ends.

      Tech Tips

      After installing the oil seal rings, check that they rotate smoothly.

  2. INSTALL FORWARD CLUTCH PISTON O-RING


    1. A01BH1UE02

      Coat 2 new O-rings with ATF, and install them onto the forward clutch piston sub-assembly.

  3. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY


    1. A01BD5P

      Coat a new O-ring with ATF, and install it onto the forward clutch assembly.

    2. A01BGRU

      While being careful not to damage the O-rings, press the forward clutch piston sub-assembly into the forward clutch assembly with both hands.

  4. INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A01BD4Z

      Install the forward clutch return spring sub-assembly.

    2. A01BF1CE02

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

      Note

      Make sure that the end gap of the snap ring is not aligned with the spring retainer claw.

  5. INSTALL FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC


    1. A01BABT

      Install the cushion plate.

    2. A01BAOCE01

      Install the 6 plates and 6 discs.

      Install in order
      P = Plate, D = Disc
      P - D - P - D - P - D - P - D - P - D - P - D

    3. Install the flange with the flat end facing downward.

    4. A01BGDY

      Install the snap ring with a screwdriver.

      Note

      Make sure that the end gap of the snap ring is not aligned with the cutout portion of the forward clutch drum.

  6. 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)