FORWARD CLUTCH (for 1KD-FTV) REASSEMBLY


  1. INSTALL INPUT SHAFT OIL SEAL RING


    1. A003B09

      Coat the 3 input shaft oil seal rings with ATF.

    2. Squeeze the ends of the 3 oil seal rings together, and then install them into the input shaft sub-assembly groove.

      Note

      Do not overspread the ring ends.

      Tech Tips

      After installing the oil seal rings, check that they rotate smoothly.

  2. INSTALL FORWARD CLUTCH PISTON O-RING


    1. A003CV6E02

      Coat 2 new O-rings with ATF, and install them onto the forward clutch piston sub-assembly.

  3. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY


    1. A003DNA

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

    2. A003GJE

      While being careful not to damage the O-rings, press the forward clutch piston sub-assembly into the forward clutch assembly with both hands.

  4. INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A003FKH

      Install the forward clutch return spring sub-assembly.

    2. A003G20E02

      Place SST on the spring retainer, and compress the forward clutch return spring sub-assembly with a press.

      Note

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

  5. INSTALL FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC


    1. A003FGR

      Install the cushion plate.

    2. A003H7JE01

      Install the 6 plates and 6 discs.

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

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

    4. A003EWO

      Install the snap ring with a screwdriver.

      Note

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

  6. 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)