Forward And Overrun Clutches

REPAIR FOR COMPONENT PARTS

Forward and Overrun Clutches

COMPONENTS

DISASSEMBLY

1.Check operation of forward clutch.
a.Install seal rings to bearing retainer, and set forward clutch drum.

b.Apply compressed air into oil hole of bearing retainer at the location as shown.
c.Check to see that retaining plate moves to snap ring.
d.If retaining plate does not contact snap ring:
- D-ring might be damaged.
- Seal lip might be damaged.
- Fluid might be leaking past piston check ball.
2.Check operation of overrun clutch.
a.Install seal rings to bearing retainer, and set forward clutch drum.

3.Remove snap ring for forward clutch from forward clutch drum using a flat-bladed screwdriver.
4.Remove retaining plate, drive plates, driven plates and dish plate for forward clutch.

5.Remove snap ring for overrun clutch from forward clutch drum using a flat-bladed screwdriver.
6.Remove retaining plate, drive plates, driven plates and dish plate for overrun clutch.

7.Set Tool (A) on spring retainer assembly, and remove snap ring (1) from forward clutch drum while compressing spring retainer assembly.
Tool number: KV-31103200 (J-39186)

CAUTION:
- Set Tool directly over return springs.
- Do not expand snap ring excessively.
8.Remove spring retainer assembly from forward clutch drum.

CAUTION:
Do not remove return springs from spring retainer.

9.Install seal rings to bearing retainer (1), and set forward clutch drum. Then apply compressed air into the oil hole at the location as shown to remove overrun clutch piston from forward clutch piston.

CAUTION:
Do not blow air in too quickly, or overrun clutch piston and
ATF could jump out. Carefully blow air little by little while protecting with lint-free cloth.

10.Install seal rings to bearing retainer (1), and set forward clutch drum. Then apply compressed air into the oil hole at the location as shown to remove forward clutch piston from forward clutch drum.

CAUTION:
Do not blow air in too quickly, or forward clutch piston and
ATF could jump out. Carefully blow air little by little while protecting with lint-free cloth.

11.Remove seal lips (1) and D-rings (2) from forward clutch piston (3) and overrun clutch piston (4).

INSPECTION

Forward Clutch and Overrun Clutch Snap Rings
Check for deformation, fatigue or damage. Replace if necessary.
Forward Clutch and Overrun Clutch Drive Plates

- Check facing for burns, cracks or damage. Replace if necessary.
- Measure thickness of facing.

CAUTION:
- Measure the thickness at 3 locations and find the average.
- Inspect all drive plates.
- Replace if the thickness is below the allowable limit.
Forward Clutch and Overrun Clutch Dish Plates
- Check for deformation or damage.

- Measure thickness (t) of dish plate. Replace if damaged, deformed or worn.

Forward Clutch and Overrun Clutch Spring Retainer Assembly

Check length (L) of spring retainer assembly. Replace if damaged, deformed or worn.
Length (L): 27.7 mm (1.091 in)

CAUTION:
Do not remove return springs (A) from spring retainer (B)
Forward Clutch Drum

- Make sure that check balls are not fixed.
- Apply compressed air to check ball oil hole from outside of forward clutch drum. Make sure air leaks past ball.
- Apply compressed air to oil hole from inside of forward clutch drum. Make sure there is no air leakage.
Overrun Clutch Piston

- Make sure that check balls are not fixed.
- Apply compressed air to check ball oil hole opposite return spring.
Make sure there is no air leakage.
- Apply compressed air to oil hole on return spring side. Make sure that air leaks through ball hole.

ASSEMBLY

1.Install seal lips (1) and D-rings (2) on forward clutch piston (3)
and overrun clutch piston (4).

CAUTION:
Be careful with the direction of seal lips (1).

2.Install overrun clutch piston on forward clutch piston by turning it slowly.

CAUTION:
Apply ATF to inner surface of forward clutch piston.

3.Install forward clutch piston with overrun clutch piston on forward clutch drum by turning it slowly.

CAUTION:
Apply ATF to inner surface of forward clutch drum.

4.Align notch in forward clutch piston with groove in forward clutch drum.

5.Install spring retainer assembly (1) on overrun clutch piston (2).

6.Set Tool (A) on spring retainer assembly, and install snap ring (1) while compressing spring retainer assembly.
Tool number: KV-31103200 (J-39186)

CAUTION:
- Set SST directly over return springs.
- Do not expand snap ring excessively.

- Do not align snap ring gap with spring retainer assembly stopper.

7.Install dish plate, driven plates, drive plates and retaining plate for overrun clutch.
(1): Snap ring (2): Retaining plate (3): Drive plate (4): Driven plate (5): Dish plate
Drive plate/Driven plate: 3/4

CAUTION:
Be careful with the order of plates.

8.Install snap ring for overrun clutch using a flat-bladed screwdriver.

9.Measure clearance between overrun clutch retaining plate and snap ring using feeler gauge. If not within allowable limit, select proper retaining plate. Refer to "Parts Information" for retaining plate selection.

Specified clearance
Standard and allowable limit:
Clutches And Brakes.

10.Install dish plate, driven plates, drive plates and retaining plate for forward clutch.
(1): Snap ring (2): Retaining plate (3): Drive plate (4): Driven plate (5): Dish plate
Drive plate/Driven plate: 5/5

CAUTION:
Be careful with the order of plates.

11.Install snap ring for forward clutch using a flat-bladed screwdriver.

12.Measure clearance between forward clutch retaining plate and snap ring using feeler gauge. If not within allowable limit, select proper retaining plate. Refer to "Parts Information" for retaining plate selection.

Specified clearance
Standard and allowable limit:
Clutches And Brakes.

13.Check operation of forward clutch and overrun clutch. Refer to
"DISASSEMBLY".