FORWARD CLUTCH (for 2KD-FTV) DISASSEMBLY


  1. FIX FORWARD CLUTCH ASSEMBLY


    1. A003E72

      Place wooden blocks, etc., to prevent forward clutch shaft from touching the work stand, and place the O/D support on them.

    2. Place the forward clutch in the O/D support.

  2. INSPECT PISTON STROKE OF FORWARD CLUTCH


    1. A003BZZE02

      Using SST and a dial indicator, measure 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 (0.024 to 0.039 in.)

      If the piston stroke is outside the standard, inspect the discs.

  3. REMOVE FORWARD MULTIPLE DISC CLUTCH DISC


    1. A003FXF

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

    2. Remove the flange, the 5 plates and the 5 discs.

    3. A003FGR

      Remove the cushion plate.

  4. 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.

  5. REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A003GJFE02

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

      SST
      09350-30020   ( 09350-07040 )

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )
    3. A003FZUE02

      Remove the piston return spring.

  6. REMOVE FRONT CLUTCH PISTON SUB-ASSEMBLY


    1. A003EBX

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

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

    3. Remove the forward clutch piston.

    4. A003DNA

      Remove the O-ring from the forward clutch drum.

  7. REMOVE FORWARD CLUTCH PISTON O-RING


    1. A003ATYE02

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

  8. INSPECT FRONT 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.

  9. REMOVE INPUT SHAFT OIL SEAL RING


    1. A003F2H

      Remove the 3 oil seal rings from the forward clutch drum groove.

  10. INSPECT INPUT SHAFT SUB-ASSEMBLY


    1. A003HFS

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

      Maximum inside diameter
      24.08 mm (0.948 in.)

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