Overdrive Direct Clutch
NOTE: For removal and installation procedures refer to "Automatic Transmission/Transaxle, Service and Repair."
Component View
DISASSEMBLY
1. Check operation of one-way clutch.
Hold the O/D direct clutch drum and turn the input shaft. Check that the input shaft turns freely clockwise and locks counterclockwise.
2. Remove overdrive direct clutch assembly from overdrive planetary gear.
3. Check piston stroke of overdrive direct clutch.
a. Place the oil pump onto the torque converter clutch, and then place the O/D direct clutch assembly onto the oil pump.
b. Using Special Service Tool (SST) 09350-30020 (09350-06120) and a dial indicator, measure the O/D direct clutch piston stroke while applying and releasing compressed air (392-785 kPa or 57-114 psi).
Piston Stroke: 1.45-1.70 mm (0.057-0.067 inch)
If the values are non-standard, inspect the discs.
4. Remove flange, plates and discs.
a. Using a screwdriver, remove the snap ring from the O/D direct clutch drum.
b. Remove the flange, 2 plates and 2 discs.
5. 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.
6. Remove overdrive direct clutch piston.
a. Place the oil pump onto the torque converter clutch and then place the O/D direct clutch onto the oil pump.
b. Hold the O/D direct clutch piston, apply compressed air to the oil pump to remove the O/D direct clutch piston.
c. Remove the O/D direct clutch piston.
HINT: If the piston is at an angle and can not be removed, press down on the side jutting out and again apply compressed air, or, wind vinyl tape around the piston end and remove it with needle nose pliers.
d. Remove the 2 O-rings from the piston.
7. Remove ring gear flange. Using a screwdriver, remove the snap ring. Remove the ring gear flange.
8. Remove retaining plate.
a. Using a screwdriver, remove the snap ring.
b. Remove the retaining plate, one-way clutch and thrust washer.
9. Remove one-way clutch from outer race.
INSPECTION
1. Inspect disc 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.
2. Check overdrive 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. Check overdrive direct clutch return spring free length together with the spring seat.
- Standard Free Length: 15.8 mm (0.622 inch)
4. Check overdrive direct clutch drum bushings.
Using a dial indicator, measure the inside diameter of the clutch drum bushings.
- Maximum Inside Diameter: 27.11 mm (1.0673 inch)
If the inside diameter is greater than the maximum, replace the clutch drum.
5. Check overdrive planetary gear bushings.
Using a dial indicator, measure the inside diameter of the planetary gear bushing.
- Maximum Inside Diameter: 11.27 mm (0.4437 inch)
If the inside diameter is greater than the maximum, replace the planetary gear.
6. Measure planetary pinion gear thrust clearance.
Using a feeler gauge, measure the planetary pinion gear thrust clearance.
- Standard Clearance: 0.20-0.60 mm (0.0078-0.0236 inch)
- Maximum Clearance: 1.00 mm (0.0393 inch)
If the clearance is greater than the maximum, replace the planetary gear assembly.
ASSEMBLY
1. Install overdrive one-way clutch.
a. Install the thrust washer to the overdrive planetary gear, the grooved side facing upward.
b. Install the one-way clutch into the outer race the flanged side of the one-way clutch facing upward.
c. Install the overdrive one-way clutch with the outer race to the overdrive planetary gear.
d. Install the retaining plate.
e. Using a screwdriver, install the snap ring.
2. Install ring gear flange to overdrive planetary ring gear.
a. Install the ring gear flange.
b. Using a screwdriver, install the snap ring.
3. Install overdrive direct clutch piston.
a. Coat new O-rings with ATF and install them on the O/D direct clutch piston.
b. Being careful not to damage the O-rings, press the direct clutch piston into the clutch drum with both hands.
4. Install piston return spring.
a. Install the piston return spring to the piston.
b. Place SST 09350-30020 (09350-07040) on the spring retainer, and compress the return spring with a press.
c. Install the snap ring with SST 09350-30020 (09350-07070). Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
5. Install plates, discs and flange.
a. Install the plates and discs.
Install in order: P=Plate D=Disc
P-D-P-D
b. Install the flange, the flat end facing downward.
c. Using a screwdriver, install the snap ring.
6. Check piston stroke of overdrive direct clutch.
a. Place the oil pump onto the torque converter clutch, then place the O/D direct clutch assembly onto the oil pump.
b. Using SST 09350-30020 (09350-06120) and a dial indicator, measure the overdrive direct clutch piston stroke while applying and releasing compressed air (392-785 kPa or 57-114 psi).
Piston stroke: 1.45-1.70 mm (0.057-0.067 inch)
- If the piston stroke is less than the limit, parts may have been assembled incorrectly, so check and reassemble again.
- If the piston stroke is nonstandard, select another flange.
HINT: There are 6 different flange thicknesses.
Flange No: Thickness.
- No.16: 3.6 mm (0.142 inch)
- No.17: 3.5 mm (0.138 inch)
- No.18: 3.4 mm (0.134 inch)
- No.19: 3.3 mm (0.130 inch)
- No.20: 3.2 mm (0.126 inch)
- No.21: 3.1 mm (0.122 inch)
7. Install overdrive direct clutch assembly.
a. Align the flukes of the discs in the direct clutch.
b. Install the direct clutch assembly onto the O/D planetary gear.
8. Check operation of one-way clutch.
Hold the O/D direct clutch drum and turn the input shaft. Check that the input shaft turns freely clockwise and locks counterclockwise.