Direct Clutch

NOTE: For removal and installation procedures refer to "Automatic Transmission/Transaxle, Service and Repair."




Component View

DISASSEMBLY





1. Check pack clearance of direct clutch.
a. Place the direct clutch assembly onto the O/D support assembly.





b. Using SST 09350-30020 (09350-06120) and a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (186-206 kPa, 1.9-2.1 kgf/cm2, 27-30 psi).
- Pack Clearance: 0.40-0.70 mm (0.0157-0.0276 inch)





2. If the values are non-standard inspect the discs.
a. Using a screwdriver, remove the snap ring from the direct clutch drum.
b. Remove the flange, 5 plates and 5 discs.





3. Remove piston return spring.
a. Place SST 09350-30020 (09350-07040) on the spring retainer and compress the return spring with a press.
b. Using SST 09350-30020 (09350-07070), remove the snap ring.
c. Remove the piston return spring.





4. Remove direct clutch piston place the direct clutch drum onto the O/D support. Hold the direct clutch piston and apply compressed air to the O/D support to remove the direct clutch piston.

HINT: Make sure the direct clutch piston is square in the drum before applying compressed air. Remove the direct clutch piston.





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

INSPECTION





1. Check direct clutch piston return spring.
Check the spring free length together with the spring seat.
Standard Free Length: 21.32 mm (0.9154 inch)





2. Check direct clutch piston.
a. Check that the check ball is free by shaking the piston.
b. Check that the valve does not leak by applying low-pressure compressed air.





3. Inspect disc, plate and flange.
Check to see If the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them.

HINT: If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace all discs.





4. Check direct clutch bushing.
Using a dial indicator, measure the inside diameter of the clutch drum bushing.
- Maximum Inside Diameter: 53.97 mm (2.1248 inch)
If the inside diameter is greater than the maximum, replace the clutch drum.

ASSEMBLY





1. Install direct clutch piston to direct clutch drum.
a. Coat new O-rings with ate and install them on the direct clutch piston.





b. Being careful not to damage the O-rings, press in the direct clutch piston into the clutch drum with both hands.





2. Install piston return spring.
a. Install the piston return spring.





b. Place SST 09350-30020 (09350-07040) on the spring retainer, and compress the return spring with a press.
c. Using SST 09350-30020 (09350-07070), install the snap ring. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.





3. Install plates, discs and flange.
a. Install the plates and discs.
Install in order: P=Plate D=Disk.
- P-D-P-D-P-D-P-D
b. Install the flange, the flat end downward.





c. Using a screwdriver, install the snap ring. Be sure the end gap of the snap ring is not aligned with the cutout portion of the direct clutch drum.





4. Check piston stroke of direct clutch.
a. Place the direct clutch assembly onto the O/D support assembly.





b. Using SST 09350-30020 (09350-06120) and a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (186-206 kPa, 27-30 psi).
Pack Clearance: 0.40-0.70 mm (0.0157-0.0276 inch)
- If the pack clearance is less than the limit, parts may have been assembled incorrectly, so check and reassemble again.
- If the pack clearance is non-standard, select another flange.

HINT: There are 9 different flange thicknesses.

Flange No: Thickness.
- No.86: 2.7 mm (0.106 inch)
- No.85: 2.8 mm (0.110 inch)
- No.84: 2.9 mm (0.114 inch)
- No.33: 3.0 mm (0.118 inch)
- No.32: 3.1 mm (0.122 inch)
- No.31: 3.2 mm (0.126 inch)
- No.30: 3.3 mm (0.130 inch)
- No.29: 3.4 mm (0.134 inch)
- No.28: 3.5 mm (0.138 inch)
- No.27: 3.6 mm (0.142 inch)
- No.34: 3.7 mm (0.146 inch)