Overdrive Direct Clutch Disassembly

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.

Using a dial indicator, measure the inside diameter of the clutch drum bushes.

Maximum inside diameter:

27.11 mm (1.07 in.)

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)

Standard piston stroke:

1.85 to 2.15 mm (0.0728 to 0.0846 in.)

Using a screwdriver, pry out the snap ring from the overdrive direct clutch drum.

Remove the flange, 2 plates and 2 discs.

Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage.

HINT:

Before assembling new discs, soak them in ATF for at least 15 minutes.

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

SST

09350-30020(09350-07040)

NOTICE:

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.

Using snap ring pliers, remove the snap ring.

Remove the piston return spring.

Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:

15.8 mm (0.622 in.)

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

Hold the overdrive direct clutch piston by hand, and apply compressed air (392 kPa (4.0 kgf/cm², 57 psi)) to the oil pump to remove the overdrive direct clutch piston.

Remove the overdrive direct clutch piston.

HINT:

If the piston is at an angle and cannot be removed, press down on the protruding side and apply compressed air again. Or, wind vinyl tape around the piston end and remove it with needle-nose pliers.

Remove the 2 O-rings from the piston.

Check that the check ball is free by shaking the piston.

Check that the valve does not have leaks by applying low-pressure compressed air.

Using a screwdriver, pry out the snap ring.

Remove the ring gear flange.

Using a screwdriver, pry out the snap ring.

Remove the retaining plate.

Using a screwdriver, pry out the snap ring.

Remove the retaining plate.

Using a dial indicator, measure the inside diameter of the planetary gear bush.

Maximum inside diameter:

11.27 mm (0.444 in.)

Using a feeler gauge, measure the planetary pinion gear thrust clearance.

Standard clearance:

0.20 to 0.60 mm (0.00787 to 0.0236 in.)

Maximum clearance:

0.65 mm (0.0256 in.)