Assembly

CAUTION: Composition clutch plates and synthetic seals should not be cleaned in a vapor degreaser or with any type of detergent cleaner. To clean these parts, wipe them off with a lint free cloth. New clutch plates or bands should be soaked in the specified transaxle fluid for two hours before being assembled.

NOTE: Clutch clearances are adjusted by the selection of snap ring thickness. If the clearance is not within specification, adjust as necessary.

1. Clean the components with a suitable solvent and use compressed air to dry all parts and clean the fluid passages. Perform the following before assembly:
- Inspect the clutch cylinder damage or wear.
- Inspect all clutches for damage or wear.
- Check the clutch piston and drum seal area for burrs or damage.





2. Measure the 3-4 drive plate facing thickness.

NOTE: Measure the facing thickness in three places and calculate the average value.

- The standard facing thickness should be 1.6 mm (0.063 inch); the minimum is 1.4 mm (0.055 inch). If not within the specification, replace the drive plates.





3. Measure the 3-4 clutch piston spring free length. If not within the specification, replace the 3-4. clutch piston spring.

NOTE: Do not compress the 3-4 clutch piston spring when measuring it with vernier calipers.





4. Inspect the 3-4 clutch piston.
- Verify that there is air flow when applying compressed air through the fluid hole on the return spring side. Apply a maximum air pressure of 392 kPa (57 psi).
- Verify that there is no air leakage when applying compressed air through the fluid hole opposite the return spring side. Apply a maximum air pressure of 392 kPa (57 psi).





5. Apply the specified transaxle fluid to the 3-4 clutch piston large seal and the 3-4 clutch piston inner seal and install the (A) 3-4 clutch piston large seal and the (B) 3-4 clutch piston inner seal.





6. Install the 3-4 clutch piston into the 3-4 clutch cylinder. Seat the 3-4 clutch piston by pushing evenly around the circumference of the piston, being careful not to damage the outer sea!.
- 3-4 clutch piston inner seal inner diameter is 53.5 mm (2.106 inch).
- 3-4 clutch piston outer seal inner diameter is 98.0 mm (3.858 inch).





7. Install the (A) 3-4 clutch piston spring retainer and the (B) 3-4 clutch piston spring.





8. Use Clutch Spring Compressor T65L-77515-A to install the 3-4 clutch return spring snap ring.
(1) Install the Clutch Spring Compressor T65L-77515-A and compress the 3-4 clutch piston spring and retainer. Compress the 3-4 clutch piston spring only enough to install the snap ring.
(2) Install the 3-4 clutch return spring snap ring.





9. Install the 3-4 clutch disc pack.
- The installation order is steel-friction-steel-friction-steel-friction-steel-friction.





10. Install the 3-4 clutch pressure plate.





11. Install the 3-4 clutch pressure plate snap ring.





12. With the 3-4 clutch assembled, check the 3-4 clutch disc pack clearance.
(1) Use a feeler gauge to measure between the 3-4 clutch pressure plate and the 3-4 clutch pressure plate snap ring. The clearance should be 1.3-1.6 mm (0.051-0.063 inch). If the clearance is not within the specification, adjust it by selecting the proper snap ring. Refer to the Snap Ring Sizes chart below.
1.4 mm (0.055 inch)
1.6 mm (0.063 inch)
1.8 mm (0.078 inch)
2.0 mm (0.079 inch)
2.2 mm (0.087 inch)
2.4 mm (0.094 inch)





13. Use Leak Check Adapter T9OP-77000-RH to check the 3-4 clutch piston operation.
(1) Install Leak Check Adapter T9OP-77000-RH to the 3-4 clutch cylinder.
(2) Apply compressed air through the Leak Check Adaptor. Apply a maximum air pressure of 392 kPa (57 psi). The 3-4 clutch should make a solid apply sound.
14. Pour the specified transaxle fluid into the 3-4 clutch cylinder until the 3-4 clutch piston is submerged. Apply compressed air through the Leak Check Adaptor T9OP-77000-RH. Apply a maximum air pressure of 392 kPa (57 psi). Verify that no bubbles come from the 3-4 clutch piston seals.





15. Apply petroleum jelly to the thrust bearings and install them on the 3-4 clutch cylinder.
- The thrust bearing outer diameter for the carrier hub side should be 56.1 mm (2.21 inch). The thrust bearing outer diameter for the output shell side should be 72.1mm (2.84 inch).