DIRECT CLUTCH REASSEMBLY


  1. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY


    1. A003EKLE02

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

    2. A003BSG

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

  2. INSTALL DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A003C53E02

      Install the return spring.

    2. A003ICKE03

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

      SST
      09350-30020   ( 09350-07040 )

    3. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note

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

  3. INSTALL DIRECT CLUTCH FLANGE


    1. A003DAJE02

      Install the cushion plate.

    2. Install the 4 plates and the 4 discs.

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

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

    4. A003G30

      Using a screwdriver, install the snap ring.

      Note

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

  4. 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 piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

      SST
      09350-30020   ( 09350-06120 )
      Pack Clearance
      0.40 to 0.70 mm (0.016 to 0.028 in.)

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

      If the pack clearance is outside the standard, select another flange.

      Tech Tips

      There are 8 different flanges in thickness.

      Flange thickness
      mm (in.)
      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)