Clutch Drum And Input Shaft Assembly Reassembly

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

Install the No. 2 clutch balancer and direct clutch return spring to the direct clutch piston.

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

Press the direct clutch piston into the clutch drum with both hands.

NOTICE:

Be careful not to damage the O-rings.

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

SST

09320-89010
09350-30020(09350-07070)

NOTICE:

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 the spring sheet from being deformed.

Install the snap ring with a snap ring expander.

NOTICE:

Do not expand the snap ring excessively.

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

NOTICE:

Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

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

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

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

NOTICE:

Be careful not to damage the O-rings.

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

Install the reverse clutch return spring onto the reverse clutch piston.

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

SST

09387-00070
09350-30020(09350-07070)

NOTICE:

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 the spring sheet from being deformed.

Install the snap ring with a snap ring expander.

NOTICE:

Do not expand the snap ring excessively.

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

NOTICE:

Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

Install the 6 plates, 5 discs and flange on the clutch drum.

Install in order:

P - P - D - P - D - P - D - P - D - P - D - F

HINT:

P = Plate

Using a screwdriver, install the 2 hole snap rings on the clutch drum.

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

Standard pack clearance:

0.5 to 0.8 mm (0.020 to 0.031 in.)

NOTICE:

When measuring the moving distance, install a standard flange (thickness: 3.4 mm (0.031 in.)) to the position of the shaded area in the illustration.

HINT:

Flange moving distance A = 0.26 to 1.14 mm (0.010 to 0.045 in.)

Pack clearance = Flange moving distance A - 0.05 mm (0.002 in.)

If the pack clearance is not within the standard, select and install a clutch flange that makes the pack clearance within the standard.

Standard flange thickness:

No.	Thickness	No.	Thickness
0	3.0 mm (0.118 in.)	5	3.5 mm (0.138 in.)
1	3.1 mm (0.122 in.)	6	3.6 mm (0.142 in.)
2	3.2 mm (0.126 in.)	7	3.7 mm (0.146 in.)
3	3.3 mm (0.130 in.)	8	3.8 mm (0.150 in.)
4	3.4 mm (0.134 in.)	-	-

Install the reverse clutch flange to the clutch drum.

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

Using a screwdriver, install the hole snap ring.

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

Standard pack clearance:

0.5 to 0.8 mm (0.020 to 0.031 in.)

NOTICE:

When measuring the moving distance, install a standard flange (thickness: 3.3 mm (0.130 in.)) to the position of the shaded area in the illustration.

HINT:

Piston stroke A = 1.05 to 2.15 mm (0.041 to 0.085 in.)

Flange moving distance B = 0.72 to 1.08 mm (0.029 to 0.043 in.)

Pack clearance = Piston stroke A - Flange moving distance B - 0.06 mm (0.002 in.)

If the pack clearance is not within the standard, select and install a clutch flange that makes the pack clearance within the standard.

Standard flange thickness:

No.	Thickness	No.	Thickness
0	2.8 mm (0.110 in.)	6	3.4 mm (0.134 in.)
1	2.9 mm (0.114 in.)	7	3.5 mm (0.138 in.)
2	3.0 mm (0.118 in.)	8	3.6 mm (0.142 in.)
3	3.1 mm (0.122 in.)	9	3.7 mm (0.146 in.)
4	3.2 mm (0.126 in.)	A	3.8 mm (0.150 in.)
5	3.3 mm (0.130 in.)	-	-

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

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

Coat 2 new O-rings with ATF, and install them on the No. 1 forward clutch piston.

Coat a new O-ring with ATF and install it on the clutch balancer.

Install the No. 1 clutch balancer and forward clutch return spring.

NOTICE:

Be careful not to damage the O-ring.

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

SST

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

NOTICE:

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 the spring sheet from being deformed.

Install the snap ring with a snap ring expander.

NOTICE:

Do not expand the snap ring excessively.

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

NOTICE:

Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

Install the 2 flanges, 6 discs and 5 plates to the input shaft assembly.

Install in order:

F- D - P - D - P - D - P - D - P - D - P - D - F

HINT:

F = Flange

D = Disc

P = Plate

Using a screwdriver, install the hole snap ring.

Coat the 3 oil seal rings with ATF.

Squeeze the ends of the 3 oil seal rings together, and then install them to the input shaft groove.

NOTICE:

Do not over-spread the ring ends.

HINT:

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

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

Standard pack clearance:

0.6 to 0.9 mm (0.024 to 0.354 in.)

NOTICE:

When measuring the moving distance, install a standard flange (thickness: 3.4 mm (0.031 in.)) to the position of the shaded area in the illustration.

HINT:

Flange moving distance A = 0.26 to 1.36 mm (0.010 to 0.054 in.)

Pack clearance = Flange moving distance A to 0.01 mm (0.0003 in.)

If the pack clearance is not within the standard, select and install a clutch flange that makes the pack clearance within the standard.

Standard flange thickness:

No.	Thickness	No.	Thickness
0	3.0 mm (0.118 in.)	6	3.6 mm (0.142 in.)
1	3.1 mm (0.122 in.)	7	3.7 mm (0.146 in.)
2	3.2 mm (0.126 in.)	8	3.8 mm (0.150 in.)
3	3.3 mm (0.130 in.)	9	3.9 mm (0.154 in.)
4	3.4 mm (0.134 in.)	A	4.0 mm (0.158 in.)
5	3.5 mm (0.138 in.)	-	-

Install the input shaft to the clutch drum.

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

Standard thrust needle roller bearing diameter:

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

Install the No. 2 thrust bearing race and input shaft thrust bearing race rear to the multiple disc clutch hub.

Standard bearing and race diameter:

Item	Inside	Outside
No. 2 thrust bearing race	38.4 mm (1.512 in.)	63.0 mm (2.480 in.)
Input shaft thrust bearing race RR	22.6 mm (0.890 in.)	60.0 mm (2.362 in.)

Install the multiple disc clutch hub to the clutch drum.

Install the 2 thrust needle roller bearings to the forward clutch hub.

Bearing and race diameter:

Item	Inside	Outside
Bearing A	42.5 mm (1.673 in.)	61.2 mm (2.409 in.)
Bearing B	33.3 mm (1.311 in.)	56.6 mm (2.228 in.)

Install the forward clutch hub to the clutch drum.

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

Install in order:

D - P - D - P - D - P - D - P - D - F

HINT:

D = Disc

P = Plate

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

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

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