K1-INPUT CLUTCH
DISASSEMBLY
| Input Clutch K1 Components |
| 1 - K1 OUTER DISC CARRIER | 7 - DISC SPRING |
| 2 - FREEWHEELING CLUTCH F1 | 8 - SPRING PLATE |
| 3 - SNAP-RING | 9 - SPRING PLATE SEALING RING |
| 4 - OUTER DISC CARRIER SEALING RING | 10 - SNAP-RING |
| 5 - PISTON SEALING RING | 11 - SNAP-RING |
| 6 - PISTON | 12 - MULTIPLE DISC PACK - REFER TO TEXT FOR CORRECT ASSEMBLY ORDER |
1. Remove snap-ring (11) from outer multiple-disc carrier (1).
2. Take multiple-disc pack (12) out of outer multiple-disc carrier (1). Note which clutch disc is removed just prior to the spring plate (8) for re-assembly. If the clutch discs are re-used, this disc must be returned to its original position on top of the spring plate.
3. Place Multi-use Spring Compressor 8900 (2) on the spring plate and compress the spring until the snap-ring (1) is exposed.
4. Remove snap-ring (1).
5. Take out disc spring (7) and remove piston (6) by carefully blowing compressed air into the drilled oil feed passage.
6. Remove snap-ring (3) and take out front freewheeling clutch F1 (2). Take care when removing the F1 clutch to prevent the clutch sprags from falling out. If this occurs, the clutch must be replaced.
ASSEMBLY
| Input Clutch K1 Components |
| 1 - K1 OUTER DISC CARRIER | 7 - DISC SPRING |
| 2 - FREEWHEELING CLUTCH F1 | 8 - SPRING PLATE |
| 3 - SNAP-RING | 9 - SPRING PLATE SEALING RING |
| 4 - OUTER DISC CARRIER SEALING RING | 10 - SNAP-RING |
| 5 - PISTON SEALING RING | 11 - SNAP-RING |
| 6 - PISTON | 12 - MULTIPLE DISC PACK - REFER TO TEXT FOR CORRECT ASSEMBLY ORDER |
1. Install piston (6) in the outer multiple-disc carrier (1). Check sealing rings (4 and 5), replace if necessary. The rounded off edges of the sealing rings must point outwards.
2. Insert disc spring (7). Insert disc spring with the curvature towards the piston.
3. Insert spring plate (8). Insert spring plate with the curvature towards the sun gear. Check sealing ring (9), replace if necessary.
4. Place Multi-use Spring Compressor 8900 (2) on spring plate and compress the spring until the groove of the snap-ring (1) is exposed.
5. Insert snap-ring (1). After installing, check snap-ring for correct seat.
CAUTION: When working with double sided friction discs, an externally lugged steel plate is installed first, followed by a friction disc, and continuing on until all the required discs are installed. When working with single sided friction discs, an externally lugged disc is installed first, followed by an internally lugged disc, and continuing on until all the required discs are installed. All single sided discs are installed with the friction side up.
NOTE: Pay attention to the sequence of discs. If the original clutch discs are reused, be sure to return the disc identified on disassembly as belonging on top of the spring plate (8) to its original location.
NOTE: Place new friction multiple-discs in ATF fluid for one hour before installing.
6. Insert multiple-disc pack (12) in the outer multiple-disc carrier.
7. Insert snap-ring (11).
8. Measure the K1 clutch pack clearance by mounting Pressing Tool 8901 (1) on outer multiple disc.
9. Using a lever press, compress pressing tool as far as the marking ring (the marking ring is still visible, see small arrow).
| 1 - OUTER MULTIPLE DISC - 1.8MM (0.071 IN.) |
| 2 - OUTER MULTIPLE DISC - 2.8MM (0.110 IN.) |
| 3 - OUTER MULTIPLE DISC - 4.0MM (0.158 IN.) |
| 4 - K1 OUTER DISC CARRIER |
| 5 - SNAP-RING |
| 6 - FRICTION DISCS |
| 7 - DISC SPRING |
| 8 - PISTON |
10. For transmissions using double sided friction discs, use a feeler gauge to determine the play "L" at three points between the snap-ring (5) and outer multiple-disc (3).
11. During the measurement the snap-ring (5) must contact the upper bearing surface of the groove in the outer multiple-disc carrier (4).
12. The correct clutch clearance for transmissions with double sided friction discs is 2.7-3.1 mm (0.106-0.122 in.) for three friction disc versions, 3.0-3.4 mm (0.118-0.134 in.) for four disc versions, 3.3-3.7 mm (0.130-0.146 in.) for five disc versions, and 3.6-4.0 mm (0.142-0.158 in.) for six disc versions.
13. Adjust with snap-ring (5), if necessary. Snap-rings are available in thicknesses of 2.6 mm (0.102 in.), 2.9 mm (0.114 in.), 3.2 mm (0.126 in.), 3.5 mm (0.138 in.), 3.8 mm (0.150 in.), and 4.1 mm (0.162 in.).
14. Insert front freewheeling clutch F1 (2) and fit snap-ring (3). The freewheeling clutch F1 (2) must be installed in the direction of the arrow.
| 1 - OUTER MULTIPLE DISCS |
| 2 - OUTER MULTIPLE DISC - 4.0MM (0.158 IN.) |
| 3 - K1 OUTER DISC CARRIER |
| 4 - SNAP-RING |
| 5 - INNER MULTIPLE DISCS |
| 6 - DISC SPRING |
| 7 - PISTON |
15. For transmissions using single sided friction discs, use a feeler gauge to determine the play "L" at three points between the snap-ring (4) and outer multiple-disc (2).
16. During the measurement the snap-ring (4) must contact the upper bearing surface of the groove in the outer multiple-disc carrier (3).
17. The correct clutch clearance for transmissions with single sided friction discs is 2.4-2.8 mm (0.095-0.110 in.) for six friction disc versions, 2.6-3.0 mm (0.102-0.118 in.) for eight disc versions, 2.8-3.2 mm (0.110-0.126 in.) for ten disc versions, and 2.9-3.3 mm (0.114-0.130 in.) for twelve disc versions.
18. Adjust with snap-ring (4), if necessary. Snap-rings are available in thicknesses of 2.6 mm (0.102 in.), 2.9 mm (0.114 in.), 3.2 mm (0.126 in.), 3.5 mm (0.138 in.), 3.8 mm (0.150 in.), and 4.1 mm (0.162 in.).
19. Insert front freewheeling clutch F1 (2) and fit snap-ring (3). The freewheeling clutch F1 (2) must be installed in the direction of the arrow.