Reverse/Forward Clutch Assembly
Reverse/forward clutch assemblyPre-inspection
Clutch operation
1. Set reverse/forward clutch assembly onto oil pump.
2. Check clutch operation by applying compressed air through fluid passages shown.
Applied air pressure: 57 psi (392 kPa, 4.0 kg/cm2) maximum
Clutch clearance
Reverse clutch
1. Measure clearance between retaining plate and snap ring.
Clearance: 0.035 - 0.047 inch (1.9 - 1.2 mm)
2. If not as specified, replace parts as necessary.
Forward clutch
1. Measure clearance between retaining plate and snap ring.
Clearance: 0.039 - 0.047 inch (1.0 - 1.2 mm)
2. If not as specified, replace parts as necessary.
Coasting clutch
1. Remove snap ring, retaining plate, drive plates, driven plates and dished plate of forward clutch.
2. Measure clearance between retaining plate and snap ring.
Clearance: 0.039 - 0.047 inch (1.0 - 1.2 mm)
3. If not as specified, replace parts as necessary.
Disassembly
1. Remove thrust bearing.
2. Remove snap ring.
3. Remove retaining plate.
4. Remove forward clutch drive plates and driven plates (three of each).
5. Remove dished plate.
6. Install SST (OK201 190 AA1/K94-4209-AT) in coasting clutch drum as shown.
7. Compress spring and retainer assembly.
8. Remove snap ring.
9. Remove SST (OK201 190 AA1/K94A-4209-AT), then remove spring and retainer assembly.
10. Remove snap ring.
11. Remove retaining plate.
12. Remove coasting clutch drive plates and driven plates (two of each).
13. Remove coasting clutch drum from reverse/forward drum by applying compressed air through fluid passage.
14. Remove coasting clutch piston from coasting clutch drum by applying compressed air through fluid passage.
15. Remove outer seal and inner seal from coasting piston.
16. Remove two seal rings and outer seal from coasting clutch drum.
17. Install SST (OK201 190 AA1/K94A-4209-AT) in reverse/forward drum as shown.
18. Compress piston return spring.
19. Remove snap ring from groove with snap ring pliers.
20. Remove SST (OK201 190 AA1/K94A-420g-AT) from reverse/forward drum.
21. Remove snap ring with a screwdriver.
22. Remove retaining plate.
23. Remove reverse clutch driven plates and driven plates (two of each).
24. Remove snap ring.
25. Remove return spring stopper and piston
26. Place reverse/forward drum on oil pump
27. Remove reverse piston by applying compressed air through reverse clutch fluid passage.
28. Remove two seal rings from reverse piston.
Inspection
Drive plates
1. Measure facing thickness in three places and determine average of three readings.
Standard: 0.063 inch (1.6 mm)
Minimum: 0.055 inch (1.4 mm)
2. If not within specification, replace drive plates
Spring and retainer assembly
1. Measure spring free length and check for deformation
Free length: 0.805 inch (20.45 mm)
2. If not within specification, replace spring and retainer assembly.
Reverse clutch piston
1. Verify that there is no air leakage when applying compressed air through oil hole opposite return spring.
2. Verify that there is air flow when applying compressed air through oil hole on return spring side
Air pressure: 57 psi (392 kPa, 4.0 kg/cm2) maximum
Coasting clutch piston
1. Verify that there is no air leakage when applying compressed air through oil hole opposite return spring.
2. Verify that there is air flow when applying compressed air through oil hole on return spring side.
Air pressure: 57 psi (392 kPa, 4.0 kg/cm2) maximum
Reverse/forward drum
1. Verify that there is air flow when applying compressed air through backside of drum.
2. Verify that there is no air leakage when applying compressed air through inside of drum.
Air pressure: 57 psi (392 kPa, 4.0 kg/cm2) maximum
Re-assembly
1. Install reverse clutch piston.
a. Apply ATF to inner and outer faces of seals, and install them to reverse clutch piston.
b. Insert reverse clutch piston by pushing evenly around circumference, being careful not to damage seal rings.
2. Install piston return spring with tabs facing away from reverse clutch piston.
3. Install return spring stop with step facing upward.
4. Install snap ring half-way down reverse/forward drum as shown.
5. Install SST (OK201 190 AA1/K94A-4209-AT) on reverse/forward drum.
6. Compress spring and retainer assembly.
7. Install snap ring with a screwdriver.
8. Remove SST (OK201 190 AA1/K94A-4209-AT).
9. Install dished plate with dished side facing downward into drum as shown.
10. Install drive and driven plates (two of each).
Notice: Installation order:
Driven-Drive-Driven-Drive
11. Install retaining plate.
12. Install snap ring.
13. Measure reverse clutch clearance.
a. Measure clearance between snap ring and retaining plate of reverse clutch.
b. If clearance is not within specification, adjust it by selecting snap ring with correct thickness.
Reverse clutch clearance: 0.035 - 0.047 inch (0.9 - 1.2 mm)
14. Install coasting clutch drum.
a Apply ATF to inner and outer faces of seal, and install it onto coasting clutch drum.
b. Face outer seal lip toward inside by gently rolling it down around circumference for easier installation into drum
c. Install coasting clutch drum in correct position in reverse/forward drum as shown.
d. Push evenly around circumference, being careful not to damage outer seal.
15. Install coasting clutch piston.
a. Apply ATF to inner and outer faces of seals and install them onto coasting clutch piston.
b. Face outer seal lip toward inside by gently rolling it down around circumference for easier installation into drum.
16. Install spring and retainer assembly.
17. Install SST (OK201 190 AA1/K94A-4207-AT) in coasting clutch as shown.
18. Compress spring and retainer assembly.
19. Install snap ring.
20. Remove SST (OK201 190 AA1/K94A-4207-AT).
21. Install dished plate with dished side facing out of drum as shown.
22. Install drive and driven plate.
Notice: Installation order:
Driven-Drive-Driven-Drive
23. Install retaining plate.
24. Install snap ring.
25. Measure coasting clutch clearance.
a. Measure clearance between snap ring and retaining plate of coasting clutch.
b. If clearance is not within specification, adjust it by selecting snap ring with correct thickness.
Coasting clutch clearance: 0.039 - 0.048 inch (1.0 - 1.2 mm)
26. Install dished plate with dished side facing downward into drum, as shown.
27. Install drive and driven plates.
Notice: Installation order:
Driven-Drive-Driven-Drive-Driven-Drive
28. Install retaining plate.
29. Install snap ring.
30. Measure forward clutch clearance.
a. Measure clearance between snap ring and retaining plate of forward clutch.
b. If clearance is not within specification, adjust it by selecting snap ring with correct thickness.
Forward clutch clearance: 0.039 - 0.048 inch (1.0 - 1.2 mm)
31. Check clutch operation as follows:
a. Set clutch assembly onto oil pump.
b. Check clutch operation by applying compressed air though fluid passages shown.
Air pressure: 57 psi (392 kPa, 4.0 kg/cm2) maximum
32. Apply petroleum jelly to thrust bearings, and secure them on each side of reverse/forward drum.
Thrust bearing outer diameter:
Oil pump side: 3.39 inch (86.0 mm)
Small sun gear and one-way clutch side: 2.21 inch (56.1 mm)