Underdrive Clutch

UNDERDRIVE CLUTCH

COMPONENTS:

DISASSEMBLY

1. REMOVE UNDERDRIVE CLUTCH FLANGE NO.1 HOLE SNAP RING
(a) Using a screwdriver, remove the underdrive clutch flange No.1 hole snap ring from the underdrive clutch drum sub-assembly.

2. REMOVE UNDERDRIVE CLUTCH DISC NO.1
(a) Remove the flange, 3 underdrive clutch disc No.1s and 3 plates from the underdrive clutch drum sub-assembly.

3. REMOVE UNDERDRIVE RETURN SPRING SHAFT SNAP RING
(a) Using SST and a press, compress the return spring retainer.
SST 09350-32014 (09351-32070)
(b) Using snap ring pliers, remove the underdrive return spring shaft snap ring.
(c) Remove the SST.

4. REMOVE UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY
(a) Remove the underdrive clutch return spring sub-assembly and underdrive clutch return spring plate from the underdrive clutch drum sub-assembly.

5. REMOVE UNDERDRIVE CLUTCH PISTON SUB-ASSEMBLY
(a) Install the underdrive clutch to the transaxle case.

HINT: 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 underdrive clutch piston sub-assembly from the underdrive clutch drum sub-assembly.
(c) If the piston does not pop out with compressed air, use needle-nose pliers to remove it.

(d) Using a screwdriver, remove the 2 underdrive clutch piston O-rings from the underdrive clutch piston sub-assembly.

6. INSPECT UNDERDRIVE CLUTCH DISC NO.1
7. INSPECT UNDERDRIVE CLUTCH PISTON SUB-ASSEMBLY
8. INSPECT UNDERDRIVE CLUTCH DRUM SUB-ASSEMBLY

INSPECTION

1. INSPECT UNDERDRIVE CLUTCH DISC NO.1
(a) Check if the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them.

HINT:
^ If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace the disc.
^ Before assembling new discs, soak them in ATF for at least 15 minutes.

2. INSPECT UNDERDRIVE CLUTCH PISTON SUB-ASSEMBLY
(a) Check that the check ball is free by shaking the underdrive clutch piston sub-assy.

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

3. INSPECT UNDERDRIVE CLUTCH DRUM SUB-ASSEMBLY
(a) Using a caliper gauge, measure the bushing inside diameter of the underdrive clutch drum sub-assy.
Standard inside diameter:
Front side: 46.500 to 46.525 mm (1.83071 to 1.83169 in.)
Rear side: 55.000 to 55.030 mm (2.16535 to 2.16653 in.)
Maximum inside diameter:
Front side: 46.570 mm (1.83346 in.)
Rear side: 55.080 mm (2.16850 in.)

REASSEMBLY

1. INSTALL UNDERDRIVE CLUTCH PISTON SUB-ASSEMBLY
(a) Coat the 2 new underdrive clutch piston O-rings with ATF and install 2 new underdrive clutch piston O-rings to the underdrive clutch piston sub-assembly.

(b) Install the underdrive clutch piston sub-assembly in to the underdrive clutch drum sub-assembly.

NOTICE: Be careful not to damage the underdrive clutch piston O-rings.

2. INSTALL UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY
(a) Install the underdrive clutch return spring plate and underdrive clutch return spring sub-assembly to the underdrive clutch drum sub-assembly.

3. INSTALL UNDERDRIVE RETURN SPRING SHAFT SNAP RING
(a) Using SST and a press, compress the return spring retainer.
SST 09350-32014 (09351-32070)
(b) Using snap ring pliers, install the underdrive return spring shaft snap ring to the underdrive clutch drum sub-assembly.
SST 09350-32014 (09351-32070)

4. INSTALL UNDERDRIVE CLUTCH DISC NO.1
(a) Install the 3 plates and 3 underdrive clutch disc No. 1s to the underdrive clutch drum sub-assembly.
Install in order:
F = Flange D = Disc P = Plate P - D - P - D - P - D - F
(b) Install the flange with the flat side facing downward.

5. INSTALL UNDERDRIVE CLUTCH FLANGE NO.1 HOLE SNAP RING
(a) Using a screwdriver, install the underdrive clutch flange No.1 hole snap ring to the underdrive clutch drum sub-assembly.