A/T Clutch Clearance Inspection (A/T)

A/T Clutch Clearance Inspection

Special Tools Required
Clutch compressor attachment ( 07ZAE-PRP0100)

1.	Inspect the clutch piston, discs, plates, and end plate for wear and damage, and inspect clutch waved-plate phase difference, if necessary.

2.	Install the clutch piston in the clutch drum. Do not install the O-rings during inspection.

3.	For K20A6 Engine model 1st Clutch: Install the waved spring (A) in the clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch waved-plates (C) (4), and discs (D) (4), and install the clutch-end-plate (E) with the flat side toward the disc. CBDAE

For K20A6 Engine model 2nd Clutch:
Install the waved spring (A) in the clutch drum (B). Install the clutch flat-plate (C), and clutch disc (D). Starting with the clutch waved-plate, alternately install the clutch waved-plates (E) (3), and discs (F) (3), and install the clutch-end-plate (G) with the flat side toward the disc.

BCDAGFE

For K20A6 Engine model 3rd Clutch:
Install the waved spring (A) in the clutch drum (B). Install the clutch flat-plate (C), and clutch disc (D). Starting with the clutch waved-plate, alternately install the clutch waved-plates (E) (3), and discs (F) (3), and install the clutch-end-plate (G) with the flat side toward the disc.

BCDAFEE

6.	For K20A6 Engine model 4th Clutch: Install the waved spring (A) in the clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch waved-plates (C) (3), and discs (D) (3), and install the clutch-end-plate (E) with the flat side toward the disc. CADBE

7.	For K20A6 Engine model 5th Clutch: Install the waved spring (A) in the clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch waved-plates (C) (3), and discs (D) (3), and install the clutch-end-plate (E) with the flat side toward the disc. CADBE

8.	For K24A3 Engine model 1st Clutch: Install the waved spring (A) in the clutch drum (B). Starting with the clutch plate, alternately install the clutch plate (C) (5) and discs (D) (5), then install the clutch-end-plate (E) with the flat side toward the disc. CBDAE

For K24A3 Engine model 2nd Clutch:
Install the waved spring (A) in the clutch drum (B). Install the 4.0 mm-thick plate (C) with the sheer droop side (D) toward the inside of the drum, clutch disc (E), and 2.0 mm-thick flat-plate (F), then starting with the disc, alternately install the discs (G) (4) and waved-plates (H) (3), then install the clutch-end-plate (I) with the flat side toward the disc.

ECFABHGID

10.	For K24A3 Engine model 3rd Clutch: Install the waved spring (A) in the clutch drum (B). Starting with the clutch plate, alternately install the clutch plate (C) (5) and discs (D) (5), then install the clutch-end-plate (E) with the flat side toward the disc. CBDAE

11.	For K24A3 Engine model 4th Clutch: Install the waved spring (A) in the clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (4) and discs (D) (4), then install the clutch-end-plate (E) with the flat side toward the disc. CBDAE

12.	For K24A3 Engine model 5th Clutch: Install the waved spring (A) in the clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (4) and discs (D) (4), then install the clutch-end-plate (E) with the flat side toward the disc. CBDAE

13.	Install the snap ring with a screwdriver.

14.	Set a dial indicator (A) on the clutch end plate (B). ACB

15.	Zero the dial indicator with the clutch end plate lifted up to the snap ring (C).

16.	Release the clutch end plate to lower the clutch end plate, then put the special tool on the end plate (A). BADC07ZAE-PRP0100

17.	Except for K24A3 engine model 1st and 3rd clutches: Press the special tool down with 150-160 N (15-16 kgf, 33-35 lbf) using a force gauge, and read the dial indicator (B).

18.	For K24A3 engine model 1st and 3rd clutches: Press the special tool down with 39 N (4.0 kgf, 9 lbf) using a force gauge, and read the dial indicator (B).

19.

The dial indicator reads the clearance (C) between the clutch end plate and top disc (D). Take measurements in at least three places, and use average as the actual clearance.

**Clutch End Plate-to-Top Disc Clearance**
K20A6 Engine model:
Service Limit:
1st Clutch:	1.23-1.43 mm (0.048-0.056 in.)
2nd Clutch:	0.75-0.95 mm (0.030-0.037 in.)
3rd Clutch:	0.83-1.03 mm (0.033-0.041 in.)
4th Clutch:	0.73-0.93 mm (0.029-0.037 in.)
5th Clutch:	0.73-0.93 mm (0.029-0.037 in.)

K24A3 Engine model:
Service Limit:
1st Clutch:	0.82-1.02 mm (0.032-0.040 in.)
2nd Clutch:	0.88-1.08 mm (0.035-0.043 in.)
3rd Clutch:	0.82-1.02 mm (0.032-0.040 in.)
4th Clutch:	0.80-1.00 mm (0.031-0.039 in.)
5th Clutch:	0.80-1.00 mm (0.031-0.039 in.)

20.

If the clearance is out of the service limit, select a new clutch end plate from the following table.

**K20A6 Engine Model: 1st and 3rd Clutch End Plates**
Plate No.	Part Number	Thickness
1	22551-PRP-003	2.3 mm (0.091 in.)
2	22552-PRP-003	2.4 mm (0.094 in.)
3	22553-PRP-003	2.5 mm (0.098 in.)
4	22554-PRP-003	2.6 mm (0.102 in.)
5	22555-PRP-003	2.7 mm (0.106 in.)
6	22556-PRP-003	2.8 mm (0.110 in.)
7	22557-PRP-003	2.9 mm (0.114 in.)
8	22558-PRP-003	3.0 mm (0.118 in.)
9	22559-PRP-003	3.1 mm (0.122 in.)
10	22560-PRP-003	3.2 mm (0.126 in.)
11	22561-PRP-003	3.3 mm (0.130 in.)
12	22562-PRP-003	3.4 mm (0.134 in.)

**K20A6 Engine Model: 2nd Clutch End Plates**
Plate No.	Part Number	Thickness
1	22571-PRP-003	2.6 mm (0.102 in.)
2	22572-PRP-003	2.7 mm (0.106 in.)
3	22573-PRP-003	2.8 mm (0.110 in.)
4	22574-PRP-003	2.9 mm (0.114 in.)
5	22575-PRP-003	3.0 mm (0.118 in.)
6	22576-PRP-003	3.1 mm (0.122 in.)
7	22577-PRP-003	3.2 mm (0.126 in.)
8	22578-PRP-003	3.3 mm (0.130 in.)
9	22579-PRP-003	3.4 mm (0.134 in.)

**K20A6 Engine Model: 4th and 5th Clutch End Plates**
Plate No.	Part Number	Thickness
11	22581-RCL-901	3.0 mm (0.118 in.)
12	22582-RCL-901	3.1 mm (0.122 in.)
13	22583-RCL-901	3.2 mm (0.126 in.)
14	22584-RCL-901	3.3 mm (0.130 in.)
15	22585-RCL-901	3.4 mm (0.134 in.)
16	22586-RCL-901	3.5 mm (0.138 in.)
17	22587-RCL-901	3.6 mm (0.142 in.)
18	22588-RCL-901	3.7 mm (0.146 in.)
19	22589-RCL-901	3.8 mm (0.150 in.)

**K24A3 Engine Model: 1st and 3rd Clutch End Plates**
Plate No.	Part Number	Thickness
F	22551-RCT-004	2.6 mm (0.102 in.)
G	22552-RCT-004	2.7 mm (0.106 in.)
H	22553-RCT-004	2.8 mm (0.110 in.)
J	22554-RCT-004	2.9 mm (0.114 in.)
K	22555-RCT-004	3.0 mm (0.118 in.)
L	22556-RCT-004	3.1 mm (0.122 in.)
M	22557-RCT-004	3.2 mm (0.126 in.)
N	22558-RCT-004	3.3 mm (0.130 in.)
P	22559-RCT-004	3.4 mm (0.134 in.)
Q	22571-RCT-004	2.6 mm (0.102 in.)
R	22572-RCT-004	2.7 mm (0.106 in.)
S	22573-RCT-004	2.8 mm (0.110 in.)
T	22574-RCT-004	2.9 mm (0.114 in.)
U	22575-RCT-004	3.0 mm (0.118 in.)
V	22576-RCT-004	3.1 mm (0.122 in.)
W	22577-RCT-004	3.2 mm (0.126 in.)
X	22578-RCT-004	3.3 mm (0.130 in.)
Y	22579-RCT-004	3.4 mm (0.134 in.)

**K24A3 Engine Model: 2nd Clutch End Plates**
Plate No.	Part Number	Thickness
1	22551-RCT-003	2.6 mm (0.102 in.)
2	22552-RCT-003	2.7 mm (0.106 in.)
3	22553-RCT-003	2.8 mm (0.110 in.)
4	22554-RCT-003	2.9 mm (0.114 in.)
5	22555-RCT-003	3.0 mm (0.118 in.)
6	22556-RCT-003	3.1 mm (0.122 in.)
7	22557-RCT-003	3.2 mm (0.126 in.)
8	22558-RCT-003	3.3 mm (0.130 in.)
9	22559-RCT-003	3.4 mm (0.134 in.)

**K24A3 Engine Model: 4th and 5th Clutch End Plates**
Plate No.	Part Number	Thickness
1	22551-PRP-003	2.1 mm (0.083 in.)
2	22552-PRP-003	2.2 mm (0.087 in.)
3	22553-PRP-003	2.3 mm (0.091 in.)
4	22554-PRP-003	2.4 mm (0.094 in.)
5	22555-PRP-003	2.5 mm (0.098 in.)
6	22556-PRP-003	2.6 mm (0.102 in.)
7	22557-PRP-003	2.7 mm (0.106 in.)
8	22558-PRP-003	2.8 mm (0.110 in.)
9	22559-PRP-003	2.9 mm (0.114 in.)

21.	Install the new clutch end plate, then recheck the clearance.

22.	If the thickest clutch end plate is installed, but the clearance is still over the service limit, replace the clutch discs and plates.