Direct Clutch Disassembly

Install the intermediate shaft and needle roller bearing onto the rear transaxle cover.

Using a dial indicator, measure the reverse clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm², 57 psi).

Standard pack clearance:

0.60 to 0.82 mm (0.0236 to 0.0323 in.)

Using a dial indicator, measure the direct clutch and overdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm², 57 psi).

Standard pack clearance:

0.61 to 0.83 mm (0.0240 to 0.0327 in.)

Using a screwdriver, remove the snap ring from the intermediate shaft.

Remove the flange, 3 discs, 3 plates and cushion plate from the intermediate shaft.

Using a screwdriver, remove the snap ring from the intermediate shaft.

Remove the flange, 4 discs and 4 plates from the intermediate shaft.

Place SST on the clutch balancer and compress the spring with a press.

SST

09387-00020

Using a snap ring expander, remove the snap ring from the direct clutch drum.

NOTICE:

1. Stop the press when the spring seat is lowered to a position 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove. This prevents the spring seat from being deformed.
   
2. Do not expand the snap ring excessively.
   

Remove the clutch balancer from the direct clutch drum.

Remove the overdrive clutch return spring from the direct clutch drum.

Install the intermediate shaft on the transaxle rear cover.

Holding the direct clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm², 57 psi) to the transaxle rear cover to remove the direct clutch piston.

Holding the direct clutch drum by hand, apply compressed air (392 kPa, 4.0 kgf/cm², 57 psi) to the transaxle rear cover to remove the direct clutch drum.

Using a screwdriver, remove the O-ring from the direct clutch drum.