DIRECT CLUTCH REASSEMBLY


  1. INSPECT DIRECT CLUTCH PISTON SUB-ASSEMBLY


    1. A01BE0Z

      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.

  2. INSPECT DIRECT CLUTCH DRUM SUB-ASSEMBLY


    1. A01BAAA

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

      Maximum inside diameter
      53.99 mm (2.1256 in.)

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

  3. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY


    1. A01BDJZ

      Coat 2 new O-rings with ATF, and install them on the direct clutch piston.

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

  4. INSTALL DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A01BE6B

      Install the return spring.

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

      SST
      09350-30020   ( 09350-07040 )

    3. Install the snap ring with SST. Be sure the end gap of the snap ring is not aligned with the spring retainer.

      SST
      09350-30020   ( 09350-07070 )

  5. INSTALL DIRECT CLUTCH FLANGE


    1. Install the 3 plates and the discs.

      Install in order
      P = Plate D = Disc
      P - D - P - D - P - D
    2. A01BB3G

      Install the flange with the flat end facing downward.

    3. Using a screwdriver, install the snap ring.

      Note

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

  6. INSPECT PISTON STROKE OF DIRECT CLUTCH


    1. A01BBQ8

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

    2. A01BHW9E01

      Using SST and a dial indicator, measure the direct clutch piston stroke while applying and releasing compressed air (392 to 785 kPa, 4.0 to 8.0 kgf/cm2, 57 to 114 psi).

      SST
      09350-30020   ( 09350-06120 )
      Piston stroke
      1.37 to 1.60 mm (0.0539 to 0.0630 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 thicknesses for the flange.

      Flange thickness:
      No. Thickness No. Thickness
      53 3.3 (0.130) 57 3.7 (0.146)
      54 3.4 (0.134) 58 3.8 (0.150)
      55 3.5 (0.138) 60 4.0 (0.157)
      56 3.6 (0.142) 62 4.2 (0.165)