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 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 transaxle case for damage or wear.
- Inspect all clutches for damage or wear.
- Check the low/reverse clutch piston and transaxle case seal area for burrs or damage.





2. Measure the low/reverse plate facing thickness. If not within 1.4-1.6 mm (0.055-0.063 inch), replace the friction plates.

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





3. Measure the free length of each spring of the low/reverse support and spring.
- The free length should be 20.2 mm (0.795 inch). If not within the specification, replace the low/reverse clutch support and spring.

NOTE: Do not compress the springs when measuring it with vernier calipers.





4. Apply the specified transaxle fluid to the inner and outer faces of the new low/reverse clutch piston outer seal and the low/reverse clutch piston inner seal. Install the inner and outer seal on the low/reverse clutch piston.
- Low/reverse clutch piston inner seal inner diameter is 140.7 mm (5.539 inch).
- Low/reverse clutch piston outer seal inner diameter is 170.5 mm (6.713 inch).





5. Install the low/reverse clutch piston into the transaxle case.
- Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the transaxle case.





6. Seat the low/reverse clutch piston by pushing evenly around the circumference of the piston, being careful not to damage the outer seal.





7. Install the low/reverse clutch support and spring.





8. Use Return Spring Compressor T88C-77000-RH to install the low/reverse clutch piston spring snap ring.
(1) Install Return Spring Compressor T88C-77000-RH and compress the low/reverse clutch support and spring. Compress the low/reverse clutch support and spring only enough to install the snap ring.
(2) Install the low/reverse clutch piston spring snap ring.





9. Install the (A) low/reverse clutch pressure plate and the (B) low/reverse clutch disc pack.
- The installation order is steel-friction-steel-friction-steel-friction-steel-friction





10. Install the low/reverse clutch pressure plate snap ring.





11. With the low/reverse clutch assembled, check the low/reverse clutch disc pack clearance.

NOTE: Take several measurements and calculate the average value.

- Use a feeler gauge to measure between the low/reverse clutch pressure plate and the low/reverse clutch pressure plate snap ring.
- The clearance should be 2.1-2.4 mm (0.083-0.094 inch). If the clearance is not within the specification, adjust it by selecting the proper snap ring. Refer to Snap Ring Sizes chart below.
2.0 mm (0.079 inch)
2.2 mm (0.087 inch)
2.4 mm (0.094 inch)
2.6 mm (0.102 inch)
2.8 mm (0.110 inch)
3.0 mm (0.118 inch)





12. To check the low/reverse clutch operation, apply compressed air through the fluid passage as shown.
- Apply a maximum air pressure of 392 kPa (57 psi).
- The clutch should make a solid apply sound, with no whistle or sign of leaks.
13. Removal of the low/reverse clutch pressure plate snap, ring, the low/reverse clutch pressure plate, and the low/reverse clutch disc pack is required for transaxle reassembly.

NOTE: Make certain the selected snap ring is identified for later assembly.