Overdrive Direct Clutch Reassembly

Install the thrust washer to the overdrive planetary gear with the groove side facing upward.

Install the 2 retainers to the one-way clutch.

Install the one-way clutch into the outer race with the flange side of the one-way clutch facing upward.

Install the overdrive one-way clutch and outer race to the overdrive planetary gear.

Install the retaining plate.

Using a screwdriver, install the snap ring.

Install the ring gear flange.

Using a screwdriver, install the snap ring.

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

Being careful not to damage the O-rings, and press in the direct clutch piston into the clutch drum with both hands.

Place SST on the spring retainer, and compress the return spring with a press.

SST

09350-30020(09350-07040)

Using a screwdriver, install the snap ring.

NOTICE:

1. Do not deform the spring sheet. Stop compressing when the spring sheet is lowered to 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove.
   
2. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
   

Install the 2 plates and discs.

Install in order:

P - D - P - D

HINT:

P = Plate

D = Disc

Install the flange with the flat end facing downward.

Using a screwdriver, install the snap ring.

Place the oil pump onto the torque converter clutch, and then place the overdrive direct clutch drum assembly onto the oil pump.

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

SST

09350-30020(09350-06120)

Piston stroke:

1.85 to 2.15 mm (0.0728 to 0.0846 in.)

HINT:

1. If the piston stroke is still not as specified, select another flange.
   
2. There are 8 different flange thicknesses.
   

Flange thickness:

No.	Thickness	No.	Thickness
08	3.8 mm (0.150 in.)	04	3.4 mm (0.134 in.)
07	3.7 mm (0.146 in.)	03	3.3 mm (0.130 in.)
06	3.6 mm (0.142 in.)	02	3.2 mm (0.126 in.)
05	3.5 mm (0.138 in.)	01	3.1 mm (0.122 in.)

Align the flukes of the discs in the direct clutch assembly.

Install the direct clutch drum assembly onto the overdrive planetary gear.

Hold the overdrive direct clutch drum, and turn the input shaft.
Check that the input shaft can be turned freely clockwise and locks when turned counterclockwise.