FORWARD CLUTCH (for 1KD-FTV) INSPECTION


  1. INSPECT PISTON STROKE OF FORWARD CLUTCH


    1. A003BZZE02

      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 (0.0236 to 0.0394 in.)

      If the piston stroke is less than the limit, parts may be assembled incorrectly, so inspect and reassemble them if necessary.

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

      Tech Tips

      There are 8 different flanges in thickness.

      Flange thickness
      No.

      Thickness

      mm (in.)

      		 No.

      Thickness

      mm (in.)
      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)

  2. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A003AZ4

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

      Standard free length
      19.17 mm (0.7547 in.)

      If the free length is shorter than the standard free length, replace the forward clutch return spring sub-assembly.

  3. INSPECT FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC


    1. A003AIS

      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.

  4. INSPECT FORWARD CLUTCH PISTON SUB-ASSEMBLY


    1. A003EXZ

      Check that the check ball is moves freely by shaking the piston.

    2. Check that the valve does not have leaks by applying low-pressure compressed air.

  5. INSPECT INPUT SHAFT SUB-ASSEMBLY


    1. A003HFS

      Using a dial indicator, measure the inside diameter of the input shaft sub-assembly bushing.

      Maximum inside diameter
      24.08 mm (0.9480 in.)

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