FORWARD CLUTCH (for 2KD-FTV) REASSEMBLY


  1. INSTALL INPUT SHAFT OIL SEAL RING


    1. A01BAWW

      Coat the 3 oil seal rings with ATF.

    2. Squeeze the ends of the 3 oil seal rings together, and then install them to the forward clutch drum groove.

      Note

      Do not over-spread 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 on the forward clutch piston.

  3. INSTALL FRONT CLUTCH PISTON SUB-ASSEMBLY


    1. A01BD5P

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

    2. A01BGRU

      Be careful not to damage the O-rings, and press the clutch piston into the forward clutch drum with both hands.

  4. REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A01BD4ZE02

      Install the piston return spring.

    2. A01BF1CE02

      Place SST on the spring retainer, and compress the return spring with a press.

      Note

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

  5. REMOVE FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC


    1. A01BABT

      Install the cushion plate.

    2. A01BCA2E01

      Install the 5 plates and 5 discs.

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

      Tech Tips

      Only the thickness of the plate on the bottom is 1.4 mm (0.055 in.) and that of the other plates is 1.8 mm (0.071 in.).

    3. Then install the flange with the flat end facing downward.

    4. A01BGDY

      Install the snap ring with a screwdriver.

      Note

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

  6. INSPECT AND ADJUST 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)