Direct Clutch Assembly Assemble

Direct Clutch Assembly Assemble

Special Tools

DT-47693-2 Dam Protector





Note:
* P = Plate (2)
* D = Disc (1)

1. Install the discs and plates to the transaxle.
Make sure you install in order - P-D-P-D-P-D
2. Temporarily install the snap ring.




3. Using a vernier caliper, measure the distance between the disc surface and snap ring surface.
4. Select an appropriate plate so that the pack clearance will meet the specified value. Refer to Transmission General Specifications (Transmission General Specifications) for standard plate thickness (a).

Standard pack clearance - 0.50-0.91 mm (0.0197-0.0358 in)

5. Piston stroke = Clearance - Plate thickness - Snap ring thickness 1.6 mm (0.063 in)





Note: Secure the snap ring so that its gap is visible through the groove of the transaxle case.

6. Temporarily remove the snap ring, attach the selected plate and restore the snap ring.




7. Coat the direct clutch piston with ATF WS, and install it to the direct clutch housing.




8. Install the direct clutch piston return spring to the direct clutch housing.




9. Install the clutch spring guide to the direct clutch housing.




10. Compress the piston return spring with a press and DT-47693-2 (1).

Note: Be sure the end gap of the snap ring is not aligned with the clutch balancer claw.

11. Using a snap ring expander, install the snap ring to the direct clutch housing.





Note:
* P = Plate (3)
* D = Disc (2)
* F = Flange (1)

12. Install the plates, discs and flange to the direct clutch housing.
Make sure you install in order - P-D-P-D-P-D-F




13. Using a screwdriver, install the snap ring.
14. Check that the end gap of the snap ring is not aligned with one of the cutouts.




15. Install the direct clutch assembly on the transaxle rear cover.
16. Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air.

Standard pack clearance - 0.515-0.825 mm (0.0203-0.0324 in)

17. If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble again. If the stroke is not as specified, select another flange.
There are six flanges in different thickness. Refer to Transmission General Specifications (Transmission General Specifications) for standard flange thickness C.





Note: Do not place the rear planetary sun gear in a vise.

18. Check that the disc rotates after inserting the rear sun gear.




19. Install the bearing race to the direct clutch housing.

* Standard inside bearing race diameter - 30.3 mm (1.193 in)
* Standard outside bearing race diameter - 46.0 mm (1.811 in)