DIRECT CLUTCH DISASSEMBLY


  1. INSPECT PACK CLEARANCE OF DIRECT CLUTCH


    1. A003HZS

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

    2. A003EQCE01

      Using SST and a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (186 to 206 kPa, 1.9 to 2.1 kgf/cm2, 27 to 30 psi).

      Pack Clearance
      0.40 to 0.70 mm (0.016 to 0.028 in.)

      If the pack clearance is outside the standard inspect the discs.

  2. REMOVE DIRECT CLUTCH FLANGE


    1. A003G30

      Using a screwdriver, remove the snap ring from the direct clutch drum.

    2. Remove the flange, the 4 plates and the 4 discs.

  3. INSPECT DIRECT CLUTCH FLANGE


    1. A003CS9E02

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

  4. REMOVE DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A003ICKE03

      Place SST on the piston return spring and compress.

      SST
      09350-30020   ( 09350-07040 )

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )
    3. A003C53

      Remove the return spring.

  5. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A003AZ4

      Measure the free length of the spring together with the spring seat.

      Standard free length
      21.32 mm (0.839 in.)

  6. REMOVE DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A003BEG

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

    2. Hold the direct clutch piston, and apply compressed air (196 kPa, 2.0 kgf/cm2, 28.5 psi) to the O/D support to remove the direct clutch piston.

      Tech Tips

      Make sure the direct clutch piston is at a right angle to the drum before applying compressed air.

    3. A003APYE02

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

  7. INSPECT DIRECT CLUTCH PISTON SUB-ASSEMBLY


    1. A003EXZ

      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.

  8. INSPECT DIRECT CLUTCH DRUM SUB-ASSEMBLY


    1. A003BNH

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

      Maximum inside diameter
      53.97 mm (2.1248 in.)

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