FORWARD CLUTCH (for 2KD-FTV) INSPECTION


  1. INSPECT PISTON STROKE OF FORWARD CLUTCH


    1. A01BB5TE02

      Using SST and a dial indicator, measure 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 (0.024 to 0.039 in.)

      If the piston stroke is outside the standard, inspect the discs.

  2. 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.

  3. INSPECT FRONT 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.

  4. REMOVE INPUT SHAFT SUB-ASSEMBLY


    1. A01BF88

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

      Maximum inside diameter
      24.08 mm (0.948 in.)

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

  5. INSTALL 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 (0.024 to 0.039 in.)

      If the piston stroke is less than the limit, parts may have been assembled incorrectly, so check and reassemble again.

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

      Tech Tips

      There are 8 different flanges in thickness.

      Flange thickness
      No. Thickness No. Thickness
      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)