Direct Clutch Reassembly

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

NOTICE:

Be careful not to damage the lip seal of the direct clutch piston.

Install the piston return spring to the direct clutch drum.

Install the clutch balancer to the direct clutch drum.

NOTICE:

Be careful not to damage the lip seal of the direct clutch balancer.

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

SST

09387-00020

Using a snap ring expander, install the snap ring to the direct clutch drum.

NOTICE:

1. Be sure the end gap of the snap ring is not aligned with the clutch balancer claw.
   
2. Stop the press when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove.
   
3. This prevents the spring sheet from being deformed.
   
4. Do not expand the snap ring excessively.
   

Install the 3 plates, 3 discs and flange to the direct clutch drum.

Install in order:

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

HINT:

P = Plate

D = Disc

F = Flange

Using a screwdriver, install the snap ring.

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

Install the direct clutch on the transaxle rear cover.

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

Standard pack clearance:

0.515 to 0.825 mm (0.0203 to 0.0324 in.)

HINT:

There are 6 flanges in different thickness.

Standard flanges in different thickness:

No.	Thickness	No.	Thickness
1	3.0 mm (.118 in.)	4	3.3 mm (0.130 in.)
2	3.1 mm (0.122 in.)	5	3.4 mm (0.134 in.)
3	3.2 mm (0.126 in.)	6	3.5 mm (0.138 in.)

Check that the disc rotates when rotating the disc after inserting the rear planetary sun gear.

NOTICE:

Do not place the rear planetary sun gear in a vise.