CLUTCH DRUM AND INPUT SHAFT ASSEMBLY REASSEMBLY


  1. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY

    A01E1ZEE01

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

    2. A01E2GME01

      Install the No. 2 clutch balancer and direct clutch return spring to the direct clutch piston sub-assembly.

    3. A01E24BE01

      Coat a new O-ring with ATF, and install them on the clutch drum sub-assembly.

    4. Be careful not to damage the O-rings. Press in the direct clutch piston into the clutch drum with both hands.

    5. A01E0YCE05

      Place SST on the direct clutch piston, and compress the return spring with a press.

      SST
      09320-89010
      09350-30020   ( 09350-07070 )

    6. Install the snap ring with a snap ring expander.

      Note


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

      • Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.

      • Do not expand the snap ring excessively.

    7. A01E07ZE03

      Set the end gap of the snap ring in the piston as shown in the illustration.

  2. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY

    A01DVCQE01

    1. Coat a new O-ring with ATF, and install it on the clutch drum sub-assembly.

    2. A01E2PBE01

      Coat a new O-ring with ATF, and install it on the reverse clutch piston sub-assembly.

    3. A01DVDSE01

      Be careful not to damage the O-ring. Press in the clutch drum sub-assembly into the reverse clutch piston with both hands.

  3. INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY

    A01DXI2E01

    1. Coat a new O-ring with ATF, and install it on the reverse clutch piston sub-assembly.

    2. Install the reverse clutch return spring onto the reverse clutch piston sub-assembly.

  4. INSTALL NO. 3 CLUTCH BALANCER

    A01E0PUE03

    1. Place SST on the No. 3 clutch balancer, and compress the clutch balancer with a press.

      SST
      09387-00070
      09350-30020   ( 09350-07070 )

    2. Install the snap ring with a snap ring expander.

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

      Note


      • Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.

      • Do not expand the snap ring excessively.

    4. A01DXBIE02

      Set the end gap of the snap ring in the piston as shown in the illustration.

  5. INSTALL DIRECT CLUTCH DISK

    A01DWQSE02

    1. Install the reverse clutch flange, 6 plates and 5 discs on the clutch drum sub-assembly.

      Install in order
      P - P - D - P - D - P - D - P - D - P - D - F

      Tech Tips

      P = Plate, D = Disc, F = Flange

    2. A01DZAZE01

      Using a screwdriver, install the 2 hole snap rings on the clutch drum sub-assembly.

  6. INSPECT PACK CLEARANCE OF DIRECT CLUTCH

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    1. Using a dial gauge, measure the moving distance (distance A) of the clutch flange at both ends across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.

      Pack clearance
      0.5 to 0.8 mm (0.020 to 0.031 in.)

      Note

      Install a selective flange (3.4 mm (0.134 in.)) when measuring the moving distance (shaded area in the illustration.)

      Tech Tips

      Flange moving distance A = 0.26 to 1.14 mm (0.010 to 0.045 in.)

      Pack clearance = Flange moving distance A - 0.05 mm (0.002 in.)

    2. If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

      Flange thickness
      No. Thickness No. Thickness
      0 3.0 mm (0.118 in.) 5 3.5 mm (0.138 in.)
      1 3.1 mm (0.122 in.) 6 3.6 mm (0.142 in.)
      2 3.2 mm (0.126 in.) 7 3.7 mm (0.146 in.)
      3 3.3 mm (0.130 in.) 8 3.8 mm (0.150 in.)
      4 3.4 mm (0.134 in.) - -

  7. INSTALL REVERSE CLUTCH FLANGE

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    1. Install the reverse clutch flange to the clutch drum sub-assembly.

  8. INSTALL REVERSE CLUTCH REACTION SLEEVE

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    1. Install the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates to the reverse clutch hub.

    2. Using a screwdriver, install the hole snap ring.

  9. INSPECT PACK CLEARANCE OF REVERSE CLUTCH


    1. Using a dial gauge, measure the reverse clutch piston stroke (distance A) and the moving distance (distance B) of the reverse flange at the both ends across a diameter while blowing air (392 kPa, 4 kgf/cm2, 57 psi) from the oil hole as shown in the illustration, and calculate the average.

      Pack clearance
      0.5 to 0.8 mm (0.020 to 0.031 in.)

      Note

      Install a selective flange (3.3 mm (0.130 in.)) when measuring the moving distance (shaded area in the illustration.)

      Tech Tips

      Piston stroke A = 1.05 to 2.15 mm (0.041 to 0.085 in.)

      Flange moving distance B = 0.72 to 1.08 mm (0.029 to 0.043 in.)

      Pack clearance = Piston stroke A to Flange moving distance B to 0.06 mm (0.002 in.)

      A01E1P9E02

    2. If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

      Flange thickness
      No. Thickness No. Thickness
      0 2.8 mm (0.110 in.) 6 3.4 mm (0.134 in.)
      1 2.9 mm (0.114 in.) 7 3.5 mm (0.138 in.)
      2 3.0 mm (0.118 in.) 8 3.6 mm (0.142 in.)
      3 3.1 mm (0.122 in.) 9 3.7 mm (0.146 in.)
      4 3.2 mm (0.126 in.) A 3.8 mm (0.150 in.)
      5 3.3 mm (0.130 in.) -

  10. REMOVE REVERSE CLUTCH REACTION SLEEVE

    A01E16RE01

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

    2. A01DVIIE01

      Remove the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates from the reverse clutch hub sub-assembly.

  11. INSTALL FORWARD CLUTCH PISTON

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    1. Coat 2 new O-rings with ATF, and install them on the No. 1 forward clutch piston.

  12. INSTALL NO. 1 CLUTCH BALANCER

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    1. Coat a new O-ring with ATF and install it on the clutch balancer.

    2. A01DYK9E01

      Install the No. 1 clutch balancer and forward clutch return spring sub-assembly.

      Note

      Be careful not to damage the O-ring.

    3. A01E00BE02

      Place SST on the No. 1 clutch balancer, and compress the return spring with a press.

      SST
      09350-30020   ( 09350-07040, 09350-07070 )

    4. Install the snap ring with a snap ring expander.

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

      Note


      • Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.

      • Do not expand the snap ring excessively.

    6. A01DV3EE02

      Set the end gap of the snap ring in the piston as shown in the illustration.

  13. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC

    A01E0B6E02

    1. Install the 2 flanges, 6 discs and 5 plates to the input shaft assembly.

    2. A01DXWCE01
      Install in order
      F- D - P - D - P - D - P - D - P - D - P - D - F

      Tech Tips

      P = Plate, D = Disc, F = Flange

      Using a screwdriver, install the hole snap ring.

  14. INSTALL INPUT SHAFT OIL SEAL RING

    A01E28UE01

    1. Coat the 3 oil seal rings with ATF.

    2. Squeeze the ends of the 3 oil seal rings together, and then install them to the starter shaft groove.

      Note

      Do not over-spread the ring ends.

      Tech Tips

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

  15. INSPECT PACK CLEARANCE OF FORWARD CLUTCH

    A01DXGBE02

    1. Using a dial gauge, measure the moving distance (distance A) of the clutch flange at boths end across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.

      Pack clearance
      0.6 to 0.9 mm (0.024 to 0.354 in.)

      Note

      Install a selective flange (3.4 mm (0.134 in.)) when measuring the moving distance (shaded area in the illustration.)

      Tech Tips

      Flange moving distance A = 0.26 to 1.36 mm (0.010 to 0.054 in.)

      Pack clearance = Flange moving distance A to 0.01 mm (0.0003 in.)

    2. If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

      Flange thickness
      No. Thickness No. Thickness
      0 3.0 mm (0.118 in.) 6 3.6 mm (0.142 in.)
      1 3.1 mm (0.122 in.) 7 3.7 mm (0.146 in.)
      2 3.2 mm (0.126 in.) 8 3.8 mm (0.150 in.)
      3 3.3 mm (0.130 in.) 9 3.9 mm (0.154 in.)
      4 3.4 mm (0.134 in.) A 4.0 mm (0.158 in.)
      5 3.5 mm (0.138 in.) -

  16. INSTALL INPUT SHAFT ASSEMBLY

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    1. Install the input shaft assembly to the clutch drum.

    2. A01DYY4E01

      Install the thrust needle roller bearing to the clutch drum assembly.

      Thrust needle roller bearing diameter
      Item Inside Outside
      Thrust needle roller bearing 21.3 mm (0.839 in.) 41.1 mm (1.618 in.)

  17. INSTALL MULTIPLE DISC CLUTCH HUB

    A01DZNNE02

    1. Install the No. 2 thrust bearing race and input shaft thrust bearing race rear to the multiple disc clutch hub.

      Bearing and race diameter
      Item Inside Outside
      Thrust bearing race No. 2 38.4 mm (1.512 in.) 63.0 mm (2.480 in.)
      Input shaft bearing race RR 22.6 mm (0.890 in.) 60.0 mm (2.362 in.)
    2. A01DVXHE01

      Install the multiple disc clutch hub to the clutch drum assembly.

  18. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY

    A01DXKOE04

    1. Install the 2 thrust needle roller bearings to the forward clutch hub sub-assembly.

      Bearing and race diameter
      Item Inside Outside
      Bearing A 42.5 mm (1.673 in.) 61.2 mm (2.409 in.)
      Bearing B 33.3 mm (1.311 in.) 56.6 mm (2.228 in.)
    2. A01DZVHE01

      Install the forward clutch hub sub-assembly to the clutch drum assembly.

  19. INSTALL REAR CLUTCH DISC

    A01E11DE05

    1. Install the clutch cushion plate, reverse clutch flange, 4 plates and 5 discs to the reverse clutch hub.

      Install in order
      D - P - D - P - D - P - D - P - D - F

      Tech Tips

      P = Plate, D = Disc, F = Flange

  20. INSTALL REVERSE CLUTCH REACTION SLEEVE

    A01DVNRE01

    1. Install the reverse clutch reaction sleeve to the reverse clutch hub.

  21. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY

    A01DW8SE01

    1. Install the reverse clutch hub sub-assembly, reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates to the clutch drum assembly.

    2. A01E1ZTE01

      Using a screwdriver, install the snap ring on the clutch drum and input shaft assembly.