Underdrive Clutch and One-Way Clutch No.3 (A240L, A241H)

COMPONENTS

DISASSEMBLY OF UNDERDRIVE CLUTCH




1. REMOVE ONE-WAY CLUTCH FROM CLUTCH DRUM
Remove the one-way clutch and thrust washer from the underdrive clutch drum.




2. REMOVE SNAP RING
Using a screwdriver, remove the snap ring




3. REMOVE FLANGE, DISCS AND PLATES
Remove the flange, discs and plates from the clutch drum.

4. REMOVE RETURN SPRING AND SPRING PLATE




a. Using SST and press, compress the return spring retainer.
SST 09350 - 32014 (09351 - 32070)




b. Using snap ring pliers, remove the snap ring.
c. Remove SST.
d. Remove the return spring and spring plate.




5. REMOVE UNDERDRIVE CLUTCH PISTON
a. Install the underdrive clutch to the transaxle case.

NOTE: Before installing the clutch, install the oil seal rings to the transaxle case.

b. Apply compressed air into the oil passage of the case, and remove the piston from the clutch drum.
c. If the piston does not pop out with compressed air, use needle-nose pliers to remove it.




6. REMOVE O-RINGS FROM PISTON
Using a screwdriver, remove the two O-rings from the underdrive clutch piston.

INSPECTION OF UNDERDRIVE CLUTCH COMPONENTS




1. INSPECT DISCS, PLATES AND FLANGES
Check if the sliding surface of the discs, plates and flanges are worn or burnt. If necessary, replace them.

NOTE:
- If the lining of the disc is exfoliated or discolored, or even a part of the printed numbers are defaced, replace the disc.
- Before assembling new discs, soak them in ATF for at least two hours.

2. INSPECT UNDERDRIVE CLUTCH PISTON




a. Check that the check ball is free by shaking the piston.




b. Check that the valve does not leak by applying low- pressure compressed air.




3. INSPECT UNDERDRIVE CLUTCH DRUM
Using a caliper gauge, measure the bushing inside diameter of the underdrive clutch drum as shown.

Standard inside diameter:
Front side 46.500 - 46.525 mm (1.83071 - 1.83169 in.)
Rear side 55.000 - 55.030 mm (2.16535 - 2.16653 in.)

Maximum inside diameter:
Front side 46.570 mm (1.83346 in.)
Rear side 55.080 mm (2.16850 in.)

ASSEMBLY OF UNDERDRIVE CLUTCH

1. INSTALL UNDERDRIVE CLUTCH PISTON INTO CLUTCH DRUM




a. Install the two new O-rings to the piston.

NOTE: Before installing, coat the O-rings with ATF.




b. Install the underdrive clutch piston into the clutch drum.

NOTE: Be careful not to damage the O-rings.

2. INSTALL SPRING SEAT AND RETURN SPRING




a. Install the spring seat and return spring to the underdrive clutch as shown.




b. Using SST and press, compress the return spring retainer.
SST 09350 - 32014 (09351 - 32070)

c. Using snap ring pliers, install the snap ring.

NOTE: Install the snap ring as shown.




d. Remove SST.
SST 09350 - 32014 (09351 - 32070)




3. INSTALL PLATES, DISCS AND FLANGE
Install in order: D=Disc P=Plate F=Flange
P-D-P-D-P-D-F

NOTE: Install the flange the flat end facing downward.




4. INSTALL SNAP RING
Install the snap ring to the underdrive clutch.




5. INSTALL ONE-WAY CLUTCH TO CLUTCH DRUM
a. Install the thrust washer to clutch drum.
b. Install the one-way clutch with the claw of retainer up.




6. CHECK OPERATION OF ONE-WAY CLUTCH
Hold the one-way clutch drum and turn the one-way clutch. Check that the one-way clutch turns freely counterclockwise and lock clockwise.