Forward Clutch Reassembly

Compress a new input shaft oil seal ring from both sides to reduce dimension A.

Dimension A:

5.0 mm (0.197 in.)

Coat the oil seal ring with ATF and install it to the forward clutch drum.

NOTICE:

Do not expand the end gap of the oil seal ring excessively. Securely engage the hooks.

Coat the forward clutch piston with ATF, and install it to the forward clutch drum.

NOTICE:

Be careful not to damage the lip of the forward clutch piston.

Install the return spring to the forward clutch drum.

NOTICE:

After installing the spring, check that all of the springs fit in the piston correctly.

Coat the clutch balancer with ATF.

Install the clutch balancer to the forward clutch drum.

NOTICE:

1. Be careful not to damage the lip of the forward clutch balancer.
   
2. Make sure that the clutch balancer is not pinched and that there are no other defects on the lip.
   
3. Apply sufficient ATF to the sealing lip before installation.
   

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

SST

09387-00020

Install the snap ring with a snap ring expander.

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

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.
   

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

NOTICE:

The end gap of the snap ring should not align with any of the stoppers.

Coat the 5 discs with ATF.

Install the 5 plates, 5 discs and flange to the forward clutch drum.

NOTICE:

Make sure that the plates, discs, and flange are installed as shown in the illustration.

Using a screwdriver, install the snap ring.

Check that the end gap of the snap ring is not aligned with one of the cutouts.

NOTICE:

The snap ring should be fully engaged in the groove of the drum.

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

Pack clearance:

1.00 to 1.25 mm (0.0394 to 0.4921 in.)

HINT:

There are 5 different thicknesses of flanges available.

Standard flange thickness:

No.	Thickness	No.	Thickness
1	3.00 mm (0.1181 in.)	4	3.45 mm (0.1358 in.)
2	3.15 mm (0.1240 in.)	5	3.60 mm (0.1417 in.)
3	3.30 mm (0.1299 in.)	-	-

Check if the disc lightly rotates when rotating the forward clutch after inserting the multiple disc clutch into it.

NOTICE:

Do not place the forward clutch in a vise.