Underdrive Clutch Reassembly

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

NOTICE:

Make sure that the O-ring is not twisted or pinched.

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

NOTICE:

1. Be careful not to damage the O-ring.
   
2. Be careful not to damage the lip of the piston.
   

Install the return spring to the underdrive clutch drum.

NOTICE:

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

Coat the clutch balancer with ATF.

Install the clutch balancer to the underdrive clutch drum.

NOTICE:

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

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

SST

09350-32014(09351-32070)

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

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 underdrive clutch drum as shown in the illustration.

NOTICE:

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

Coat the 4 discs with ATF.

Install the 4 plates, 4 discs and flange to the underdrive clutch drum.

NOTICE:

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

Using a screwdriver, install the underdrive clutch flange No. 2 hole 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.

Install the underdrive clutch to the transaxle case.

NOTICE:

Be careful not to damage the oil seal rings.

Install a dial indicator as shown in the illustration.

Measure the underdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm², 57 psi).

Standard pack clearance:

1.51 to 1.71 mm (0.0594 to 0.0673 in.)

HINT:

There are 5 different thicknesses of flanges available.

Standard flange thickness:

Mark	Thickness	Mark	Thickness
1	3.0 mm (0.118 in.)	4	3.6 mm (0.142 in.)
2	3.2 mm (0.126 in.)	5	3.8 mm (0.150 in.)
3	3.4 mm (0.134 in.)	-	-