Reassembly
CLUTCH DRUM AND INPUT SHAFT ASSEMBLYREASSEMBLY
1. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY
a. Coat 2 new O-rings with ATF, and install them in the direct clutch piston.
b. Coat a new O-ring with ATF, and install it to the clutch balancer No. 2.
c. Install the clutch balancer No. 2 and the direct clutch return spring to the direct clutch piston subassembly.
d. Press the direct clutch piston into the clutch drum by hands.
NOTICE: Dot not damage the O-rings.
e. Place SST on the direct clutch piston, and compress the return spring with a press.
SST 09320-89010, 09350-30020 (09350-07070)
f. Install the snap ring with a snap ring expander.
NOTICE:
^ 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 inch) from the snap ring groove not to deform the spring sheet.
^ Do not expand the snap ring excessively.
g. Set the end gap of the snap ring in the piston as shown in the illustration.
2. INSTALL REVERSE CLUTCH PISTON SUB ASSEMBLY
a. Coat a new O-ring with ATF, and install it on the clutch drum sub-assembly.
b. Coat a new O-ring with ATF, and install it on the reverse clutch piston sub-assembly.
c. Press the clutch drum sub-assembly into the reverse clutch piston with both hands.
NOTICE: Do not damage the O-ring.
3. INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY
a. Coat a new O-ring with ATF, and install it on the reverse clutch piston sub-assembly.
b. Install the reverse clutch return spring onto the reverse clutch piston sub-assembly.
4. INSTALL CLUTCH BALANCER NO. 3
a. Install the clutch balancer No. 3 to the reverse clutch return spring.
b. Place SST on the clutch balancer No. 3, and compress the clutch balancer with a press.
SST 09387-00070
c. Install the snap ring with a snap ring expander.
SST 09350-30020 (09350-07070)
NOTICE:
^ 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 inch) from the snap ring groove not to deform the spring sheet.
^ Do not expand the snap ring excessively.
d. Set the end gap of the snap ring in the piston as shown in the illustration.
5. INSTALL DIRECT CLUTCH DISC
a. Install the reverse clutch flange, the 5 plates and the 5 discs on the clutch drum sub-assembly
Install in order:
P = Plate, D = Disc, F = Flange,
F-D-P-D-P-D-P-D-P-D-P
b. Using a screwdriver, install the 2 hole snap rings on the clutch drum sub-assembly.
6. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
7. INSTALL REVERSE CLUTCH FLANGE
a. Install the reverse clutch flange to the clutch drum sub-assembly.
8. INSTALL REVERSE CLUTCH REACTION SLEEVE
a. Install the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 5 reverse clutch discs, and the 4 clutch plates to the reverse clutch hub.
Install in order:
P = Plate, D = Disc, F = Flange, S = Sleeve, C Cushion Plate
S-C-F-D-P-D-P-D-P-D-P-D
b. Using a screwdriver, install the hole snap ring.
9. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
10. REMOVE REVERSE CLUTCH REACTION SLEEVE
a. Using a screwdriver, remove the snap ring from the clutch drum assembly
b. Remove the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 5 reverse clutch discs, and the 4 clutch plates from the reverse clutch hub sub-assembly.
11. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY
a. Install the coast clutch piston to the forward clutch piston.
b. Install the O-ring to the forward clutch.
c. Install the forward clutch piston sub-assembly to the input shaft.
12. INSTALL CLUTCH BALANCER NO. 1
a. Coat a new D-ring with ATF and install it on the clutch balancer No. 1.
b. Install the clutch balancer No. 1 and the forward clutch return spring sub-assembly.
NOTICE: Do not damage the D-ring.
c. Place SST on the clutch balancer No. 1, and compress the return spring with a press.
SST 09350-30020 (09350-07040), 09316-20011
d. Using SST, Install the snap ring.
SST 09350-30020 (09350-07070)
NOTICE:
^ Be sure that 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 inch) from the snap ring groove not to deform the spring sheet.
^ Do not expand the snap ring excessively.
e. Set the end gap of the snap ring in the piston as shown in the illustration.
13. INSTALL COAST CLUTCH DISC
a. Install the flange, the 4 discs and the 4 plates to the forward clutch piston.
b. Using a screwdriver, install the hole snap ring.
14. INSPECT PACK CLEARANCE OF COAST CLUTCH
15. INSTALL FORWARD CLUTCH HUB CLUTCH DISC
a. Install the flange, the 4 discs 4 plates and cushion plate to the input shaft assembly.
Install in order:
P = Plate, D = Disc, F = Flange, C = Cushion
Plate F-D-P-D-P-D-P-D-P-C
b. Using a screwdriver, install the hole snap ring.
c. Install the thrust needle roller bearing and the thrust bearing race.
16. INSTALL INPUT SHAFT OIL SEAL RING
a. Coat the 4 oil seal rings with ATF.
b. Squeeze the ends of the 4 oil seal rings together, and then install them to the input shaft groove.
NOTICE: Do not expand the ring ends excessively.
HINT: After installing the oil seal rings, check that they rotate smoothly.
17. INSPECT PACK CLEARANCE OF FORWARD CLUTCH
18. INSTALL INPUT SHAFT ASSEMBLY
a. Install the input shaft assembly to the clutch drum.
Thrust Needle Roller Bearing Diameter:
b. Install the thrust needle roller bearing and the thrust bearing race to the clutch drum assembly.
19. INSTALL COAST CLUTCH HUB SUB-ASSEMBLY
a. Install the clutch hub thrust washer and the 1 way No. 4 clutch assembly to the coast clutch hub.
b. Install the coast clutch hub sub-assembly to the clutch drum assembly.
20. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY
a. Install the 2 thrust needle roller bearings and thrust bearing race No. 2 to the forward clutch hub sub assembly.
Bearing And Race Diameter:
b. Install the clutch hub thrust washer and forward clutch hub sub-assembly to the clutch drum assembly.
21. INSTALL REAR CLUTCH DISC
a. Install the clutch cushion plate, the reverse clutch flange, the 4 plates and the 5 discs to the reverse clutch hub.
22. INSTALL REVERSE CLUTCH REACTION SLEEVE
a. Install the reverse clutch reaction sleeve to the reverse clutch hub.
23. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY
a. Install the reverse clutch hub sub-assembly, the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 5 reverse clutch discs, and the 4 clutch plates to the clutch drum assembly.
b. Using a screwdriver, install the snap ring on the clutch drum and the input shaft assembly.