CLUTCH DRUM AND INPUT SHAFT ASSEMBLY > REASSEMBLY

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1. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY


    D028816

  1. Coat 2 new O-rings with ATF, and install them in the direct clutch piston.



    D028517

  1. Install the clutch balancer No.2 and the direct clutch return spring to the direct clutch piston sub-assembly.

  1. Press the direct clutch piston into the clutch drum by hands.

    NOTICE:
    Do not damage the O-rings.



    D031401E01

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

    SST
    09320-89010  
    09350-30020   (09350-07070)

  1. Install the snap ring with a snap ring expander.

    NOTICE:
    1. Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
    2. Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent spring sheet deformation.
    3. Do not expand the snap ring excessively.



    D028536E02

  1. Set the end gap of the snap ring in the piston as shown in the illustration.



2. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY


    D028513

  1. Coat a new O-ring with ATF, and install it on the clutch drum sub-assembly.



    D028512

  1. Coat a new O-ring with ATF, and install it on the reverse clutch piston sub-assembly.



    D028511

  1. Press the clutch drum sub-assembly into the reverse clutch piston with both hands.

    NOTICE:
    Do not damage the O-ring.



3. INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY

  1. Coat a new O-ring with ATF, and install it on the reverse clutch piston sub-assembly.



    D028510

  1. Install the reverse clutch return spring onto the reverse clutch piston sub-assembly.



4. INSTALL CLUTCH BALANCER NO.3


    D028509E02

  1. Install the clutch balancer No.3 to the reverse clutch return spring.

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

    SST
    09387-00050  
    09387-00070  

  1. Install the snap ring with a snap ring expander.

    SST
    09350-30020   (09350-07070)

    NOTICE:
    1. Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
    1. Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent spring sheet deformation.
    1. Do not expand the snap ring excessively.



    D031539E02

  1. Set the end gap of the snap ring in the piston as shown in the illustration.



5. INSTALL DIRECT CLUTCH DISC


    D028508E02

  1. Install the reverse clutch flange, the 6 plates and the 5 discs on the clutch drum sub-assembly.

    Install in order:
    P = Plate, D = Disc, F = Flange
    F - D - P - D - P - D - P - D - P - D - P - P



    D028507

  1. Using a screwdriver, install the 2 hole snap rings on the clutch drum sub-assembly.



6. INSPECT PACK CLEARANCE OF DIRECT CLUTCH


    D029841E02

  1. Inspect the pack clearance of the direct clutch.

    1. Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across the diameter while blowing air to the oil hole as shown in the illustration, and calculate the average.

      HINT:
      Flange moving distance A = 0.26 to 1.14 mm
      Pack clearance = Flange moving distance A - 0.05 mm

      Pack Clearance:
      0.5 to 0.8 mm (0.020 to 0.031 in.)

      NOTICE:
      Install a selective flange (t = 3.4 mm) 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 9 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
      		3.0 mm (0.118 in.)
      1
      		3.1 mm (0.122 in.)
      2
      		3.2 mm (0.126 in.)
      3
      		3.3 mm (0.130 in.)
      4
      		3.4 mm (0.134 in.)
      5
      		3.5 mm (0.138 in.)
      6
      		3.6 mm (0.142 in.)
      7
      		3.7 mm (0.146 in.)
      8
      		3.8 mm (0.150 in.)



7. INSTALL REVERSE CLUTCH FLANGE


    D028506

  1. Install the reverse clutch flange to the clutch drum sub-assembly.



8. INSTALL REVERSE CLUTCH REACTION SLEEVE


    D031540E02

  1. Install the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 5 reverse clutch discs, and the 4 clutch plates to the reverse clutch hub.

    Install in order:
    P = Plate, D = Disc, F = Flange, S = Sleeve, C = Cushion Plate
    S - C - F - D - P - D - P - D - P - D - P - D

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



9. INSPECT PACK CLEARANCE OF REVERSE CLUTCH


  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.


      D028538E02

      HINT:
      Piston stroke A = 1.05 to 2.15 mm
      Flange moving distance B = 0.72 to 1.08 mm
      Pack clearance = Piston stroke A - Flange moving distance B - 0.06

      Pack Clearance:
      0.5 to 0.8 mm (0.020 to 0.031 in.)

      NOTICE:
      Install a selective flange (t = 3.3 mm) 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 11 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
      		2.8 mm (0.110 in.)
      1
      		2.9 mm (0.114 in.)
      2
      		3.0 mm (0.118 in.)
      3
      		3.1 mm (0.122 in.)
      4
      		3.2 mm (0.126 in.)
      5
      		3.3 mm (0.130 in.)
      6
      		3.4 mm (0.134 in.)
      7
      		3.5 mm (0.138 in.)
      8
      		3.6 mm (0.142 in.)
      9
      		3.7 mm (0.146 in.)
      A
      		3.8 mm (0.150 in.)



10. REMOVE REVERSE CLUTCH REACTION SLEEVE


    D029844

  1. Using a screwdriver, remove the snap ring from the clutch drum assembly.



    D029843

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



11. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY


    D031383

  1. Install the coast clutch piston to the forward clutch piston.

  1. Install the O-ring to the forward clutch.

  1. Install the forward clutch piston sub-assembly to the input shaft.



12. INSTALL CLUTCH BALANCER NO.1


    D028523

  1. Coat a new O-ring with ATF and install it on the clutch balancer No.1.



    D031520

  1. Install the clutch balancer No.1 and the forward clutch return spring sub-assembly.

    NOTICE:
    Do not damage the O-ring.



    D031412E01

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

    SST
    09350-30020   (09350-07040, 09350-07070)

  1. Install the snap ring with a snap ring expander.

    NOTICE:
    1. Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
    1. Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent spring sheet deformation.
    1. Do not expand the snap ring excessively.



    D031536E02

  1. Set the end gap of the snap ring in the piston as shown in the illustration.



13. INSTALL COAST CLUTCH DISC


    C109355E01

  1. Install the flange, the 3 discs and the 3 plates to the forward clutch piston.

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



14. INSPECT PACK CLEARANCE OF COAST CLUTCH


    D028537E02

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

    1. Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across the diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.

      HINT:
      Flange moving distance A = 0.38 to 1.48 mm (0.01496 to 0.0583 in.)
      Pack clearance = Flange moving distance A - 0.02 mm (0.0008 in.)

      Pack Clearance:
      0.3 to 0.6 mm (0.012 to 0.024 in.)

      NOTICE:
      Install a selective flange (t = 3.0 mm) 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 10 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
      		3.0 mm (0.118 in.)
      1
      		3.1 mm (0.122 in.)
      2
      		3.2 mm (0.126 in.)
      3
      		3.3 mm (0.130 in.)
      4
      		3.4 mm (0.134 in.)
      5
      		3.5 mm (0.138 in.)
      6
      		3.6 mm (0.142 in.)
      7
      		3.7 mm (0.146 in.)
      8
      		3.8 mm (0.150 in.)
      9
      		3.9 mm (0.154 in.)



15. INSTALL FORWARD CLUTCH HUB CLUTCH DISC


    C109356E01

  1. Install the flange, the 4 discs, the 4 plates and cushion plate to the input shaft assembly.

    Install in order:
    P = Plate, D = Disc, F = Flange, C = Cushion Plate
    F - D - P - D - P - D - P - D - P - C



    D028519

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



    D031523

  1. Install the thrust needle roller bearing and the thrust bearing race.

    		Inside
    		Outside
    Thrust needle roller bearing
    		21.3 mm (0.839 in.)
    		41.1 mm (1.618 in.)
    Thrust bearing race No.2
    		22.6 mm (0.890 in.)
    		44.8 mm (1.764 in.)



16. INSTALL INPUT SHAFT OIL SEAL RING


    D031399

  1. Coat 4 new oil seal rings with ATF.

  1. Squeeze the ends of the 4 oil seal rings, and then install them to the input shaft groove.

    NOTICE:
    Do not expand the ring ends excessively.

    HINT:
    After installing the oil seal rings, check that they rotate smoothly.



17. INSPECT PACK CLEARANCE OF FORWARD CLUTCH


  1. Inspect the pack clearance of the forward clutch.



      D031403E02

    1. Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across the diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.

      HINT:
      Flange moving distance A = 0.36 to 1.50 mm
      Pack clearance = Flange moving distance A - 0.11 mm

      Pack Clearance:
      0.56 to 0.86 mm (0.0220 to 0.0339 in.)

      NOTICE:
      Install a selective flange (t = 3.4 mm) 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 11 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
      		3.0 mm (0.118 in.)
      1
      		3.1 mm (0.122 in.)
      2
      		3.2 mm (0.126 in.)
      3
      		3.3 mm (0.130 in.)
      4
      		3.4 mm (0.134 in.)
      5
      		3.5 mm (0.138 in.)
      6
      		3.6 mm (0.142 in.)
      7
      		3.7 mm (0.146 in.)
      8
      		3.8 mm (0.150 in.)
      9
      		3.9 mm (0.154 in.)
      A
      		4.0 mm (0.158 in.)



18. INSTALL INPUT SHAFT ASSEMBLY


    D031522

  1. Install the input shaft assembly to the clutch drum.



    D031521

  1. Install the thrust needle roller bearing to the clutch drum assembly.

    Thrust needle roller bearing diameter:

    		Inside
    		Outside
    Thrust needle roller bearing
    		21.3 mm (0.839 in.)
    		41.1 mm (1.618 in.)



19. INSTALL COAST CLUTCH HUB SUB-ASSEMBLY


    D031381E01

  1. Install the underdrive 1 way clutch, clutch hub thrust washer and the input shaft rear thrust bearing race to the coast clutch hub.

    Bearing and race diameter:

    		Inside
    		Outside
    Input shaft rear thrust bearing race
    		22.6 mm (0.890 in.)
    		44.8 mm (1.764 in.)



    D031377

  1. Install the coast clutch hub sub-assembly to the clutch drum assembly.



20. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY


    C109367E01

  1. Install the 2 thrust needle roller bearings and thrust bearing race No.3 to the forward clutch hub sub-assembly.

    Bearing and race diameter:

    		Inside
    		Outside
    Bearing A
    		42.5 mm (1.673 in.)
    		61.2 mm (2.409 in.)
    Bearing B
    		35.6 mm (1.402 in.)
    		56.6 mm (2.228 in.)
    Thrust bearing race No.3
    		35.6 mm (1.402 in.)
    		56.6 mm (2.228 in.)



    D031376

  1. Install the clutch hub thrust washer and forward clutch hub sub-assembly to the clutch drum assembly.



21. INSTALL REAR CLUTCH DISC


    D027999E03

  1. Install the clutch cushion plate, the reverse clutch flange, the 4 plates and the 5 discs to the reverse clutch hub.



22. INSTALL REVERSE CLUTCH REACTION SLEEVE


    D027998

  1. Install the reverse clutch reaction sleeve to the reverse clutch hub.



23. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY


    D027997

  1. Install the reverse clutch hub sub-assembly, the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 5 reverse clutch discs, and the clutch plates to the clutch drum assembly.



    D027996

  1. Using a screwdriver, install the snap ring on the clutch drum and the input shaft assembly.