CLUTCH DRUM AND INPUT SHAFT ASSEMBLY > DISASSEMBLY

for Preparation Click here

1. Place the oil pump onto the torque converter clutch, and then place the clutch drum and input shaft onto the oil pump.
   

1. Using a screwdriver, remove the snap ring from the clutch drum and input shaft.
   

2. Remove the reverse clutch hub sub-assembly with the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 5 rear clutch discs, and the 4 clutch plates from the forward clutch hub.
   

1. Remove the reverse clutch reaction sleeve from the reverse clutch hub sub-assembly.
   

1. Remove the clutch cushion plate, the reverse clutch flange, the 4 plates and the 5 discs from the reverse clutch hub.
   

1. Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt.
   If necessary, replace them.
   

   NOTICE:

   1. If the linings of the discs are peeled off or discolored, or even a part of the printed numbers is damaged, replace all discs.
      
   1. Before assembling new discs, soak them in ATF for at least 15 minutes.
      

1. Inspect the pack clearance of the reverse clutch hub sub-assembly.
   
   

   
   
   

   1. Using a dial indicator, measure the reverse clutch piston stroke (distance A) and the moving distance (distance B) of the reverse clutch flange at both ends across the diameter while blowing air (392 kPa, 4 kgf/cm², 57 psi) from the oil hole as shown in the illustration, and calculate the average.
      
      

      
      
      
      

      HINT:

      Piston stroke A = 1.90 to 3.00 mm (0.0748 to 0.1181 in.)

      Flange moving distance B = 1.38 to 1.86 mm (0.0543 to 0.0732 in.)

      Pack clearance = Piston stroke A - Flange moving distance B - 0.03 (0.0012 in.)

      Pack Clearance:

      0.5 to 0.8 mm (0.020 to 0.031 in.)
      

      NOTICE:

      Install a selective flange {t = 2.8 mm (0.110 in.)} when measuring the moving distance. (shaded area in the illustration)

   2. If the pack clearance is outside the standard, select and install a clutch flange that brings the pack clearance within the standard.
      

      HINT:

      There are 12 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

      Flange thickness:

      No.	Thickness
      0	2.4 mm (0.094 in.)
      1	2.5 mm (0.098 in.)
      2	2.6 mm (0.102 in.)
      3	2.7 mm (0.106 in.)
      4	2.8 mm (0.110 in.)
      5	2.9 mm (0.114 in.)
      6	3.0 mm (0.118 in.)
      7	3.1 mm (0.122 in.)
      8	3.2 mm (0.126 in.)
      9	3.3 mm (0.130 in.)
      A	3.4 mm (0.134 in.)
      B	3.5 mm (0.138 in.)

1. Remove the forward clutch hub sub-assembly and thrust washer from the clutch drum assembly.
   

2. Remove the 2 thrust needle roller bearings and the thrust bearing race from the forward clutch hub sub-assembly.
   

1. Using a dial indicator, measure the inside diameter of the forward clutch hub bushing.
   

   Standard inside diameter:

   23.037 to 23.062 mm (0.907 to 0.908 in.)
   

   If the inside diameter is greater than the standard inside diameter, replace the forward clutch hub.
   

1. Remove the coast clutch hub sub-assembly from the clutch drum sub-assembly.
   

1. Hold the coast clutch hub and turn the 1 way clutch assembly.
   

2. Check that the 1 way clutch assembly turns freely clockwise and locks counterclockwise.
   If there is a problem with the 1 way clutch, replace it.
   

1. Remove the 1 way No.4 clutch assembly and the clutch hub thrust washer from the coast clutch hub.
   

1. Using a screwdriver, remove the hole snap ring.
   

2. Remove the flange, cushion plate, 4 discs and 5 plates from the input shaft.
   

1. Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt.
   If necessary, replace them.
   

   NOTICE:

   1. If the linings of the discs are peeled off or discolored, or even a part of the printed numbers is damaged, replace all discs.
      
   1. Before assembling new discs, soak them in ATF for at least 15 minutes.
      

1. Using a screwdriver, remove the hole snap ring.
   

2. Remove the flange, the 4 discs and the 4 plates from the input shaft.
   

1. Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt.
   If necessary, replace them.
   

   NOTICE:

   1. If the linings of the discs are peeled off or discolored, or even a part of the printed numbers is damaged, replace all discs.
      
   1. Before assembling new discs, soak them in ATF for at least 15 minutes.
      

1. Remove the thrust needle roller bearing and the thrust bearing race from the input shaft.
   

2. Remove the input shaft from the clutch drum.
   

3. Remove the thrust needle roller bearing and thrust bearing race from the clutch drum.
   

1. Remove the 4 oil seal rings from the input shaft.
   

1. Place SST on the clutch balancer No.1, and compress the return spring with a press.
   

   SST

   09350-30020   (09350-07040)
   09316-20011  
   

2. Using SST and press, remove the snap ring.
   

   SST

   09350-30020   (09350-07070)
   

3. Remove the clutch balancer No.1 and the forward clutch return spring from the input shaft.
   

4. Remove the D-ring from the clutch balancer No.1.
   

1. Using vernier calipers, measure the free length of the spring together with the spring seat.
   

   Standard free length:

   26.29 mm (1.035 in.)
   

   If the free length is shorter than the standard free length, replace the clutch return spring sub-assembly.
   

1. Holding the forward clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm², 57 psi) to the input shaft to remove the forward clutch piston.
   

2. Remove the coast clutch piston from the forward clutch piston.
   

3. Remove the O-ring from the forward clutch piston.
   

1. Remove the reverse clutch flange from the clutch drum assembly.
   

1. Using a screwdriver, remove the 2 hole snap rings from the clutch drum assembly.
   

2. Remove the direct clutch flange, the 5 plates and the 5 discs from the clutch drum assembly.
   

1. Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt.
   If necessary, replace them.
   

   NOTICE:

   1. If the linings of the discs are peeled off or discolored, or even a part of the printed numbers is damaged, replace all discs.
      
   1. Before assembling new discs, soak them in ATF for at least 15 minutes.
      

1. Place SST on the clutch balancer No.3, and compress the return spring with a press.
   

   SST

   09387-00070  
   

2. Using SST and press, remove the snap ring.
   

   SST

   09350-30020   (09350-07070)
   

3. Remove the clutch balancer No.3.
   

1. Remove the reverse clutch return spring and the O-ring from the reverse clutch piston.
   

1. Using vernier calipers, measure the free length of the spring together with the spring seat.
   

   Standard free length:

   21.03 mm (0.828 in.)
   

   If the free length is shorter than the standard free length, replace the clutch return spring sub-assembly.
   

1. Remove the reverse clutch piston sub-assembly from the clutch drum sub-assembly.
   

2. Remove the O-ring from the reverse clutch piston sub-assembly.
   

3. Remove the O-ring from the clutch drum sub-assembly.
   

1. Place SST on the direct clutch piston, and compress the return spring with a press.
   

   SST

   09350-30020   (09350-07070)
   09518-36020  
   

2. Using SST and press, remove the snap ring.
   

3. Remove the clutch balancer No.2 and the direct clutch return spring sub-assembly.
   

4. Remove the O-ring from the clutch balancer No.2.
   

5. Using 2 screwdrivers, remove the direct clutch piston sub-assembly from the clutch drum.
   

6. Remove the 2 O-rings from the direct clutch piston sub-assembly.
   

1. Using vernier calipers, measure the free length of the spring together with the spring seat.
   

   Standard free length:

   20.02 mm (0.788 in.)
   

   If the free length is shorter than the standard free length, replace the clutch return spring sub-assembly.