Reassembly

U241E AUTOMATIC TRANSAXLE: FORWARD CLUTCH: REASSEMBLY

REASSEMBLY

1. INSTALL INPUT SHAFT OIL SEAL RING





(a) Compress the oil seal ring from both sides to reduce dimension A.
Dimension A:
5.0 mm (0.197 in.)
(b) Coat the oil seal ring with ATF and install it onto the input shaft.
2. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY





(a) Coat 2 new O-rings with ATF, and install them onto the forward clutch piston.





(b) Install the forward clutch piston into the forward clutch drum.
3. INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY





(a) Place the forward clutch return spring onto the forward clutch piston.





(b) Place SST on the return spring, and compress the return spring with a press.
SST: 09350-32014
09351-32070
(c) Install the snap ring with a snap ring expander. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
NOTICE:
- Stop the press when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove.
- This prevents the spring sheet from being deformed.
- Do not expand the snap ring excessively.

4. INSTALL FORWARD CLUTCH FLANGE HOLE SNAP RING





(a) Install the 5 plates, 5 discs and flange.
Install order:
P - D - P - D - P - D - P - D - P - D - F
HINT:
P = Plate
D = Disc
F = Flange





(b) Using a screwdriver, install the snap ring.
(c) Check that the end gap on the snap ring is not aligned with one of the cutouts.
5. INSPECT PACK CLEARANCE OF FORWARD CLUTCH





(a) Install the forward clutch on the oil pump.
NOTICE: Be careful not to damage the oil seal ring of oil pump.

(b) Using a dial indicator, measure the forward clutch piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Standard pack clearance:
1.74 to 2.08 mm (0.0685 to 0.0819 in.)
If the piston stroke is less than the minimum, the parts may have been assembled incorrectly. Check and reassemble again.
If the clearance is not as specified, select another flange.
HINT: There are 5 flanges in different thickness.

Standard flange thickness:






6. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC





(a) Inspect the clutch disc rotation.
(1) After inserting the multiple disc clutch into the multiple disc clutch hub, rotate the forward clutch and check that the disc lightly rotates.
NOTICE: Do not place the forward clutch in a vise.