Part 1

CLUTCH DRUM AND INPUT SHAFT ASSEMBLY

COMPONENTS (Part 1):

COMPONENTS (Part 2):

DISASSEMBLY

1. FIX CLUTCH DRUM AND INPUT SHAFT
(a) Place the oil pump onto the torque converter clutch, and then place the clutch drum and input shaft onto the oil pump.

2. REMOVE REVERSE CLUTCH HUB SUB-ASSEMBLY
(a) Using a screwdriver, remove the snap ring from the clutch drum and input shaft.

(b) Remove the reverse clutch hub with the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 rear clutch discs and 4 clutch plates from the forward clutch hub.

3. REMOVE REVERSE CLUTCH REACTION SLEEVE
(a) Remove the reverse clutch reaction sleeve from the reverse clutch hub.

4. REMOVE REAR CLUTCH DISC
(a) Remove the cushion plate, flange, 5 discs and 4 plates from the reverse clutch hub.
5. INSPECT REAR CLUTCH DISC
6. INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY

7. REMOVE FORWARD CLUTCH HUB SUB-ASSEMBLY
(a) Remove the forward clutch hub and thrust washer from the clutch drum assembly.

(b) Remove the 2 thrust needle roller bearings and No. 3 thrust bearing race from the forward clutch hub.
8. INSPECT FORWARD CLUTCH HUB SUB-ASSEMBLY

9. REMOVE COAST CLUTCH HUB SUB-ASSEMBLY
(a) Remove the coast clutch hub from the clutch drum.
10. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY

11. REMOVE UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(a) Remove the underdrive 1-way clutch, clutch hub thrust washer and thrust bearing race from the coast clutch hub.

12. REMOVE FORWARD CLUTCH HUB CLUTCH DISC
(a) Using a screwdriver, remove the hole snap ring.

(b) Remove the flange, 4 discs, 4 plates and cushion plate from the input shaft.
13. INSPECT FORWARD CLUTCH HUB CLUTCH DISC

14. REMOVE COAST CLUTCH DISC
(a) Using a screwdriver, remove the hole snap ring.

(b) Remove the flange, 3 discs and 3 plates from the input shaft.
15. INSPECT COAST CLUTCH DISC

16. REMOVE INPUT SHAFT
(a) Remove the thrust needle roller bearing from the input shaft.

(b) Remove the input shaft from the clutch drum.

17. REMOVE INPUT SHAFT OIL SEAL RING
(a) Remove the 4 oil seal rings from the input shaft.

18. REMOVE NO. 1 CLUTCH BALANCER
(a) Place SST on the clutch balancer, and compress the return spring with a press.
SST 09350-30020 (09350-07040)
(b) Using SST, remove the snap ring.
SST 09350-30020 (09350-07070)

(d) Remove the O-ring from the clutch balancer.
19. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

20. REMOVE FORWARD CLUTCH PISTON SUB-ASSEMBLY
(a) Holding the forward clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the input shaft to remove the forward clutch piston.

(b) Remove the coast clutch piston from the forward clutch piston.
(c) Remove the O-ring from the forward clutch piston.

21. REMOVE REVERSE CLUTCH FLANGE
(a) Remove the reverse clutch flange from the clutch drum.

22. REMOVE DIRECT CLUTCH DISC
(a) Using a screwdriver, remove the 2 hole snap rings from the clutch drum assembly.

(b) Remove the flange, 5 discs and 6 plates from the clutch drum.
23. INSPECT DIRECT CLUTCH DISC

24. REMOVE NO. 3 CLUTCH BALANCER
(a) Place SST on the clutch balancer, and compress the return spring with a press.
SST 09387-00070
(b) Using SST, remove the snap ring.
SST 09350-30020 (09350-07070)
(c) Remove the clutch balancer.

25. REMOVE REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY
(a) Remove the reverse clutch return spring and O-ring from the reverse clutch piston.
26. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY

27. REMOVE REVERSE CLUTCH PISTON SUB-ASSEMBLY
(a) Remove the reverse clutch piston from the clutch drum.

(b) Remove the O-ring from the reverse clutch piston.

28. REMOVE DIRECT CLUTCH PISTON SUB-ASSEMBLY
(a) Place SST on the direct clutch piston, and compress the return spring with a press.
SST 09320-89010
(b) Using SST, remove the snap ring.
SST 09350-30020 (09350-07070)

(d) Remove the No. 2 clutch balancer and direct clutch return spring from the direct clutch piston.

(e) Remove the 2 O-rings from the direct clutch piston.
29. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY

INSPECTION

1. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(a) Hold the coast clutch hub and turn the 1-way clutch.
(b) Check that the 1-way clutch turns freely counterclockwise and locks clockwise.
If there is a problem with the 1-way clutch, replace it.

2. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY
(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.
Standard free length: 19.51 mm (0.768 in.)
If the free length is not as specified, replace the clutch return spring sub-assembly.

3. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY
(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.
Standard free length: 21.04 mm (0.828 in.)
If the free length is not as specified, replace the clutch return spring sub-assembly.

4. INSPECT DIRECT CLUTCH DISC
(a) Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage.

NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes.

5. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
(a) Inspect the pack clearance of the direct clutch.
(1) Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across the diameter while blowing air into the oil hole as shown in the illustration, and calculate the average.

HINT:
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.)

Standard pack clearance: 0.5 to 0.8 mm (0.020 to 0.031 in.)

NOTICE: When measuring the moving distance, install a standard flange (thickness: 3.4 mm, 0.134 in.) to the position of the shaded area shown in the illustration.

(2) If the pack clearance is not as specified, select and install a clutch flange that brings the pack clearance within the standard.

HINT: There are 9 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

Flange thickness:

6. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
(a) Inspect the pack clearance of the reverse clutch hub.
(1) Using a dial indicator, measure the reverse clutch piston stroke (distance A) and moving distance (distance B) of the reverse clutch flange at both ends across the diameter while blowing air (392 kPa, 4 kgf/cm2, 57 psi) into the oil hole as shown in the illustration, and calculate the average.

HINT:
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 (0.028 to 0.043 in.)
Pack clearance = Piston stroke A - Flange moving distance B - 0.06 mm (0.002 in.)

Standard pack clearance: 0.5 to 0.8 mm (0.020 to 0.031 in.)

NOTICE: When measuring the moving distance, install a standard flange (thickness: 3.3 mm, 0.130 in.) to the position of the shaded area shown in the illustration.

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

HINT: There are 11 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

Standard flange thickness:

7. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY
(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.
Standard free length: 24.64 mm (0.9701 in.)
If the free length is not as specified, replace the clutch return spring sub-assembly.

8. INSPECT COAST CLUTCH DISC
(a) Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage.

NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes.

9. INSPECT PACK CLEARANCE OF COAST CLUTCH
(a) Inspect the pack clearance of the coast clutch hub.
(1) Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across the diameter while blowing air into the oil hole as shown in the illustration, and calculate the average.

HINT:
Flange moving distance A = 0.38 to 1.48 mm (0.01496 to 0.0583 in.)
Pack clearance = Flange moving distance A -0.02 mm (0.0008 in.)
Standard pack clearance: 0.3 to 0.6 mm (0.012 to 0.024 in.)

NOTICE: When measuring the moving distance, install a standard flange (thickness: 3.0 mm, 0.018 in.) to the position of the shaded area shown in the illustration.

(2) If the pack clearance is not as specified, select and install a clutch flange that brings the pack clearance within the standard.

HINT: There are 10 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

Standard flange thickness:

10. INSPECT FORWARD CLUTCH HUB CLUTCH DISC
(a) Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage.

NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes.

11. INSPECT PACK CLEARANCE OF FORWARD CLUTCH
(a) Inspect the pack clearance of the forward clutch.
(1) Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across the diameter while blowing air into the oil hole as shown in the illustration, and calculate the average.

HINT:
Flange moving distance A = 0.36 to 1.50 mm (0.142 to 0.0591 in.)
Pack clearance = Flange moving distance A - 0.11 mm (0.0043 in.)
Standard pack clearance: 0.56 to 0.86 mm (0.0220 to 0.0339 in.)

NOTICE: When measuring the moving distance, install a standard flange (thickness: 3.4 mm, 0.134 in.) to the position of the shaded area shown in the illustration.

(2) If the pack clearance is not as specified, select and install a clutch flange that brings the pack clearance within the standard.

HINT: There are 11 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

Standard flange thickness:

12. INSPECT FORWARD CLUTCH HUB SUB-ASSEMBLY
(a) Using a caliper gauge, measure the inside diameter of the forward clutch hub bush.
Standard inside diameter: 26.037 to 26.062 mm (1.0251 to 1.0261 in.)
If the inside diameter is not as specified, replace the forward clutch hub sub-assembly.

13. INSPECT REAR CLUTCH DISC
(a) Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage.

NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes.

14. INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY
(a) Using a caliper gauge, measure the inside diameter of the reverse clutch hub bush.
Standard inside diameter: 35.812 to 35.837 mm (1.4099 to 1.4109 in.)
If the inside diameter is not as specified, replace the reverse clutch hub sub-assembly.