Part 2

CLUTCH DRUM AND INPUT SHAFT ASSEMBLY(continued)

COMPONENTS (Part 1):

COMPONENTS (Part 2):

REASSEMBLY





1. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY
(a) Coat 2 new O-rings with ATF, and install them in the direct clutch piston.





(b) Install the No. 2 clutch balancer and direct clutch return spring to the direct clutch piston.
(c) Press the direct clutch piston into the clutch drum by hand.

NOTICE: Do not damage the O-rings.





(d) Place SST on the direct clutch piston, and compress the return spring with a press.
SST 09320-89010
(e) 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 seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent spring seat deformation.
^ Do not expand the snap ring excessively.





(f) 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.





(b) Coat a new O-ring with ATF, and install it on the reverse clutch piston.





(c) Press the clutch drum 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.





(b) Install the reverse clutch return spring onto the reverse clutch piston.





4. INSTALL NO. 3 CLUTCH BALANCER
(a) Install the clutch balancer to the reverse clutch return spring.
(b) Place SST on the clutch balancer, and compress the clutch balancer with a press.
SST 09387-00070
(c) 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 in.) from the snap ring groove to prevent spring sheet deformation.
^ 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 6 plates, 5 discs and flange on the clutch drum.
Install in order: P - P - D - P - D - P - D - P - D - P - D - F

HINT:
P = Plate
D = Disc
F = Flange





(b) Using a screwdriver, install the 2 hole snap rings on the clutch drum.
6. INSPECT PACK CLEARANCE OF DIRECT CLUTCH





7. INSTALL REVERSE CLUTCH FLANGE
(a) Install the flange to the clutch drum.





8. INSTALL REVERSE CLUTCH REACTION SLEEVE
(a) Install the 5 discs, 4 plates, flange, cushion plate and sleeve to the reverse clutch hub.
Install in order: D - P - D - P - D - P - D - P - D - F - C - S

HINT:
D = Disc
P = Plate
F = Flange
C = Cushion Plate
S = Sleeve

(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.





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





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 to the input shaft.





12. INSTALL NO. 1 CLUTCH BALANCER
(a) Coat a new O-ring with ATF and install it on the clutch balancer.





(b) Install the clutch balancer and forward clutch return spring.

NOTICE: Do not damage the O-ring.





(c) Place SST on the clutch balancer, and compress the return spring with a press.
SST 09350-30020 (09350-07040)
(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 in.) from the snap ring groove to prevent spring sheet deformation.
^ 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 3 plates, 3 discs and flange to the forward clutch piston.
Install in order: P - D - P - D - P - D - F

HINT:
P = Plate
D = Disc
F = Flange

(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, 4 discs, 4 plates and cushion plate to the input shaft.
Install in order: C - P - D - P - D - P - D - P - D - F

HINT:
C = Cushion Plate
P = Plate
D = Disc
F = Flange





(b) Using a screwdriver, install the hole snap ring.





(c) Install the thrust needle roller bearing and thrust bearing race.

Standard bearing and race diameter:

16. INSTALL INPUT SHAFT OIL SEAL RING
(a) Coat 4 new oil seal rings with ATF.
(b) Squeeze the ends of the 4 oil seal rings, 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 to the clutch drum.





(b) Install the thrust needle roller bearing to the clutch drum.

Standard thrust needle roller bearing diameter:

19. INSTALL COAST CLUTCH HUB SUB-ASSEMBLY
(a) Install the underdrive 1-way clutch, clutch hub thrust washer and input shaft rear thrust bearing race to the coast clutch hub.

Standard bearing race diameter:

(b) Install the coast clutch hub to the clutch drum.





20. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY
(a) Install the 2 thrust needle roller bearings and No. 3 thrust bearing race to the forward clutch hub.

Standard bearing and race diameter:

(b) Install the clutch hub thrust washer and forward clutch hub to the clutch drum.





21. INSTALL REAR CLUTCH DISC
(a) Install the 5 discs, 4 plates, flange and cushion plate to the reverse clutch hub.
Install in order: D - P - D - P - D - P - D - P - D - F - C

HINT:
D = Disc
P = Plate
F = Flange
C = Cushion plate





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, reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and clutch plates to the clutch drum.





(b) Using a screwdriver, install the snap ring on the clutch drum and input shaft.