Part 2

Shafts and Clutches (cont'd)

Intermediary Shaft Disassembly, Inspection, and Reassembly

Special Tools Required
Driver, 40 mm I.D. 07746-0030100

1. Remove the 26.5 mm washer, the snap ring, the cotter retainer, and the cotters from the intermediary shaft.





2. Remove the intermediary shaft 4th gear using a press, and disassemble the shaft and gears.
3. Inspect the bearings for galling and rough movement.
4. Check the shaft bearing surfaces for scoring and excessive wear, and check the shaft splines for excessive wear and damage.
5. Check the sealing rings for excessive wear and damage.
6. Check the 3rd gear axial clearance, and the intermediary shaft installation height.
7. Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.
8. Lubricate all parts with ATF, and reassemble the shaft and gears.
9. Install the press-fitted 4th gear using the driver, 40 mm and a press in the direction shown.

Intermediary Shaft 4th Gear Removal

1. Place 4th gear (A) on press bases (B), and place a shaft protector (C) between the intermediary shaft (D) and the press to prevent damaging the intermediary shaft.





2. Support the intermediary shaft with one hand, then press the intermediary shaft out of the press-fitted 4th gear. The intermediary shaft will drop down after pressing it out of the press-fitted gear.
3. Remove the remaining parts from the intermediary shaft.

Intermediary Shaft 4th Gear Installation

Special Tools Required
Driver, 40 mm I.D. 07746-0030100

1. Wrap the shaft splines with tape, and install new O-rings in the 3rd clutch O-ring grooves, then remove the tape.
2. Install the 3rd clutch, the 53 mm splined washer, the thrust needle bearing, the needle bearing, 3rd gear, the thrust needle bearing on the intermediary shaft.
3. Install 4th gear (A) using the driver, 40 mm and a press.





4. Install the 19.8 mm cotters, the cotter retainer, and the snap ring.
5. Install the 26.5 mm washer on the top of the intermediary shaft.

Intermediary Shaft 3rd Gear Axial Clearance Inspection

Special Tools Required
Driver, 40 mm I.D. 07746-0030100

1. Install the 3rd clutch (A), the 53 mm splined washer (B), the thrust needle bearing (C), the needle bearing (D), 3rd gear (E), and the thrust needle bearing (F) on the intermediary shaft (G). Do not install the O-rings during inspection.








2. Install 4th gear (H) using the driver, 40 mm and a press.
3. Install the cotters (I), the cotter retainer (J), and the snap ring (K).
4. Set the dial indicator (A) on 3rd gear (B).





5. Measure the 3rd gear axial clearance in at least three places while moving the 3rd gear. Use the average as the actual clearance.





6. If the clearance is out of standard, remove the splined washer and measure its thickness.
7. Select and install a new splined washer, then recheck the clearance.





Intermediary Shaft Installation Height Inspection/Adjustment

1. Install the intermediary shaft (A) in the torque converter housing, and install the 26.5 mm washer (B) on the intermediary shaft.








2. Install a new gasket (C) on the torque converter housing.
3. Measure the installed height (D) of the intermediary shaft between the surface (E) of the gasket and the surface of the 26.5 mm washer (F).
4. If the clearance is out of standard, remove the 26.5 mm washer and measure its thickness.
5. Select and install a new washer, then recheck the installation height.





Clutch Disassembly

Special Tools Required
^ Clutch spring compressor attachment 07LAE-PX40100 or 07HAE-PL50101
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A

1. Remove the snap ring (A) using a screwdriver (B).





2. Remove the 1st clutch end-plate (A), the 1st clutch discs (B) (5), the 1st clutch wave-plates (C) (5), the disc spring (D), 1st-hold clutch plate B (E), the 1st hold clutch discs (F) (3), the 1st-hold clutch wave-plates (G) (2), and the 1st-hold clutch flat-plate (H) from the 1st/1st-hold clutch drum (I).





3. Make reference marks on the clutch wave-plates.
4. Remove the clutch end-plate (A), the clutch discs (B) (7), the clutch wave-plates (C) (3), and the clutch flat-plates (D) (4) from the 2nd clutch drum (E).





5. Make reference marks on the clutch wave-plates.
6. Remove the clutch end-plate (A), the clutch discs (B) (5), the clutch wave-plates (C) (2), the clutch flat plates (D) (3), and the disc spring (E) from the 3rd clutch drum (F).





7. Make reference marks on the clutch wave-plates.
8. Remove the clutch end-plate (A), the clutch discs (B) (4), the clutch wave-plates (C) (2), the clutch flat plates (D) (2), and the disc spring (E) from the 4th clutch drum (F).





9. Make reference marks on the clutch wave-plates.
10. Remove the clutch end-plate (A), the clutch discs (B) (5), the clutch wave-plates (C) (2), the clutch flat plates (D) (3), and the disc spring (E) from the 5th clutch drum (F).





11. Make reference marks on the clutch wave-plates.
12. Install the clutch spring compressor attachment and the clutch spring compressor bolt assembly.





13. Be sure the clutch spring compressor attachment (A) is adjusted to have full contact with the spring retainer (B) on the 1st, 2nd, and 4th clutches.





14. If either end of the clutch spring compressor attachment is set over an area of the spring retainer that is unsupported by the return spring, the retainer may be damaged.





15. Set the clutch spring compressor attachment (A) on the spring retainer (B) of the 3rd and 5th clutches so the clutch spring compressor attachment works on the clutch return spring (C).





16. If either end of the clutch spring compressor attachment is not set over the clutch return spring end (A), the retainer may be damaged.





17. Compress the return spring until the snap ring can be removed.





18. Remove the snap ring using the snap ring pliers.





19. Remove the clutch spring compressor attachment and the clutch spring compressor bolt assembly.
20. Remove the snap ring (A), the spring retainer (B), and the return spring (C).





21. Wrap a shop rag around the clutch drum, and apply air pressure to the fluid passage to remove the piston. Place a finger tip on the other passage while applying air pressure.





22. Remove the 1st/1st-hold clutch piston (A) from the clutch drum (B), and remove the O-rings from the 1st clutch piston.





23. Remove the 1st-hold clutch piston (A) from the 1st clutch piston (B), and remove the O-rings from the 1st-hold clutch piston.





24. Remove the clutch piston, and remove the O-rings from the 2nd, 3rd, 4th, and 5th clutch pistons.





Clutch Inspection

1. Inspect the clutch pistons and the clutch piston check valves (A).





2. If the clutch piston check valve is loose or damaged, replace the clutch piston.
3. Check the spring retainer for wear and damage.
4. If the spring retainer is worn or damaged, replace it.
5. Inspect the clutch discs, the clutch plates, and the clutch end-plate for wear, damage, and discoloration.

Clutch Discs:
Standard Thickness: 1.94 mm (0.076 in.)

Clutch Flat-plates and Clutch Wave-plates
Standard Thickness:
1st Clutch: 1.6 mm (0.063 in.)
1st-hold Clutch: 1.8 mm (0.071 in.)
2nd Clutch: 1.8 mm (0.071 in.)
3rd Clutch: 2.0 mm (0.079 in.)
4th Clutch: 1.6 mm (0.063 in.)
5th Clutch: 1.6 mm (0.063 in.)

6. If the clutch discs are worn or damaged, replace them as a set. If the clutch discs are replaced, inspect the clearance between the clutch end-plate and the top disc.
7. If any plate is worn, damaged, or discolored, replace the damaged plate with a new plate, and inspect the other wave plates for a phase difference. If the clutch plate is replaced, inspect the clearance between the clutch end-plate and the top disc.
8. If the clutch end-plate is worn, damaged, or discolored, inspect the clearance between the clutch end-plate and the top disc, then replace the clutch end-plate.

Clutch Wave-plate Phase Difference Inspection

1. Place the clutch wave-plate (A) on a surface plate, and set a dial indicator (B) on the wave-plate.





2. Find the bottom (C) of a phase difference of the wave-plate, zero the dial indicator and make a reference mark on the bottom of the wave-plate.
3. Rotate the clutch wave-plate of the 1st, 1st-hold, 2nd, 4th, and 5th clutches about 60-degrees apart from the bottom while holding the wave-plate by its circumference, and rotate the 3rd clutch wave plate about 72-degrees or 54-degrees apart from the bottom while holding the wave-plate by its circumference. The dial indicator should be at the top (D) of a phase difference. Do not rotate the wave-plate while holding its surface, always rotate it by holding its circumference.
4. Read the dial indicator. The dial indicator reads the phase difference (E) of the wave-plate between the bottom and the top.

Standard Phase Difference:
1st Clutch: 0.17-0.30 mm (0.007-0.012 in.)
1st-hold, Clutch: 0.10-0.20 mm (0.004-0.008 in.)
2nd Clutch: 0.11-0.21 mm (0.004-0.008 in.)
3rd Clutch: 0.10-0.20 mm (0.004-0.008 in.)
4th Clutch: 0.10-0.20 mm (0.004-0.008 in.)
5th Clutch: 0.11-0.13 mm (0.004-0.005 in.)

5. Rotate the wave-plate of the 1st, 1st-hold 2nd, 4th, and 5th clutches about 60-degrees and the 3rd clutch wave-plate about 54-degrees or 72-degrees, The dial indicator should be at the bottom of a phase difference (F and G), and zero the dial indicator.
6. Measure the phase difference at the other two tops (H and I) of the wave-plate by following steps 3 thru 5.
7. If two of the three measurements are within the standard, the wave-plate is OK. If two of the three measurements are out of the standard, replace the wave-plate.

Clutch Clearance Inspection

Special Tools Required
Clutch compressor attachment 07ZAE-PRP0100

1. Inspect the clutch piston, the discs, the plates, and the end-plate for wear and damage, and inspect the clutch wave-plate phase difference, if necessary.
2. Install the 1st-hold clutch piston in the 1st clutch piston, and install the 1st/1st-hold clutch piston (A) in the 1st/1st-hold clutch drum (B). Do not install the O-rings on the clutch pistons during inspection.





3. Install the 1st-hold clutch flat-plate (A), alternately install the clutch discs (B) (3) and the 1st-hold clutch wave-plates (C) (2), then install 1st-hold clutch plate B (D) with the flat side down in the direction shown.





4. Measure the 1st-hold clutch plate B-to-top disc clearance using a feeler gauge (A) while pressing 1st-hold clutch plate B down. Take measurements in at least three places, and use the average as the actual clearance.





5. If the clearance is out of standard, replace the 1st hold clutch plates and the discs as a set, then recheck.
6. Install the disc spring (A) on 1st-hold clutch plate B in the direction shown. Starting with the 1st clutch wave-plate, alternately install the wave-plates (B) (5) and the discs (C) (5) in the 1st clutch drum (D), then install the clutch end-plate (E) with the flat side down.





7. Install the clutch pistons in the 2nd, 3rd, 4th, and 5th clutch drums. Do not install the O-rings on the clutch pistons during inspection.





8. Starting with the 2nd clutch flat-plate, alternately install the flat-plates (A) (4) and the discs (B) (4) in the 2nd clutch drum (C), and alternately install the wave-plates (D) (3) and the discs (B) (3). Install the clutch end-plate (E) with the flat side down on the top disc.





9. Install the disc spring (A) in the 3rd clutch drum (B) in the direction shown. Starting with the 3rd clutch flat-plate, alternately install the flat-plates (C) (3) and the discs (D) (3), and alternately install the wave-plates (E) (2) and the discs (D) (2). Install the clutch end-plate (F) with the flat side down on the top disc.





10. Install the disc spring (A) in the 4th clutch drum (B) in the direction shown. Starting with the 4th clutch flat-plate, alternately install the flat-plates (C) (2) and the discs (D) (2), and alternately install the wave-plates (E) (2) and the discs (D) (2). Install the clutch end-plate (F) with the flat side down on the top disc.





11. Install the disc spring (A) in the 5th clutch drum (B) in the direction shown. Starting with the 5th clutch flat-plate, alternately install the flat-plates (C) (3) and the discs (D) (3), and alternately install the wave-plates (E) (2) and the discs (D) (2). Install the clutch end-plate (F) with the flat side down on the top disc.





12. Install the snap ring using a screwdriver to secure the clutch end-plate.





13. Set a dial indicator (A) on the clutch end-plate (B).





14. Zero the dial indicator with the clutch end-plate lifted up to the snap ring (C).
15. Release the clutch end-plate to lower the clutch end-plate, then put the clutch compressor attachment on the end-plate (A).





16. Press the clutch compressor attachment down with 150 - 160 N (15 - 16 kgf, 33 - 35 lbf) (B) using a force gauge, and read the dial indicator (C).
17. The dial indicator reads the clearance (D) between the clutch end-plate and the top disc (E). Take measurements in at least three places, and use the average as the actual clearance.

Clearance between the Clutch End-plate and the Top Disc
Service Limit:
1st Clutch: 1.15-1.35 mm (0.045-0.053 in.)
2nd Clutch: 1.05-1.25 mm (0.041-0.049 in.)
3rd Clutch: 0.80-1.00 mm (0.031-0.039 in.)
4th Clutch: 0.75-0.95 mm (0.030-0.037 in.)
5th Clutch: 0.75-0.95 mm (0.030-0.037 in.)

18. If the clearance is out of the service limit, select anew clutch end-plate from the following table.




















19. Install a new clutch end-plate, then recheck the clearance. If the thickest clutch end-plate is installed, but the clearance is still over the service limit, replace the clutch discs and the plates.

Clutch Reassembly

Special Tools Required
^ Clutch spring compressor attachment 07LAE-PX40100 or 07HAE-PL50101
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A

1. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.
2. Install new O-rings (A) on the 1st-hold clutch piston (B), and install the 1st-hold clutch piston in the 1st clutch piston (C).





3. Install new O-rings (A) on the 1st clutch piston (B), and install the 1st/1st-hold clutch piston in the 1st/1st-hold clutch drum (C) while applying pressure and rotating to ensure proper seating. Do not pinch the O-ring.





4. Install the O-rings (A) on the 2nd, 3rd, 4th, and 5th clutch piston (B).





5. Install the clutch pistons in the clutch drums (C) while applying pressure and rotating to ensure proper seating. Do not pinch the O-ring.
6. Install the return spring (A) and the spring retainer (B), and position the snap ring (C) on the spring retainer.





7. Install the clutch spring compressor attachment and the clutch spring compressor bolt assembly.





8. Be sure the clutch spring compressor attachment (A) is adjusted to have full contact with the spring retainer (B) on the 1st, 2nd, and 4th clutches.





9. If either end of the clutch spring compressor attachment is set over an area of the spring retainer that is unsupported by the return spring, the retainer may be damaged.





10. Set the clutch spring compressor attachment (A) on the spring retainer (B) of the 3rd and 5th clutches so the clutch spring compressor attachment works on the clutch return spring (C).





11. If either end of the clutch spring compressor attachment is not set over the clutch return spring end (A), the retainer may be damaged.





12. Compress the return spring until the snap ring can be installed.





13. Install the snap ring using the snap ring pliers.





14. Remove the clutch spring compressor attachment and the clutch spring compressor bolt assembly.
15. Install the 1st-hold clutch flat-plate (A), alternately install the clutch discs (B) (3) and the 1st-hold clutch wave-plates (C) (2) in the 1st/1st-hold clutch drum (D), then install 1st-hold clutch plate B (E) with the flat side down in the direction shown.





16. Install the disc spring (F) on 1st-hold clutch plate B in the direction shown. Starting with the 1st clutch wave plate, alternately install the wave-plates (G) (5) and the discs (H) (5), then install the clutch end-plate (1) with the flat side down on the top disc.
17. Starting with the 2nd clutch flat-plate, alternately install the flat-plates (A) (4) and the discs (B) (4) in the 2nd clutch drum (C), and alternately install the wave plates (D) (3) and the discs (B) (3). Install the clutch end-plate (E) with the flat side down on the top disc.





18. Install the disc spring (A) in the 3rd clutch drum (B) in the direction shown. Starting with the 3rd clutch flat plate, alternately install the flat-plates (C) (3) and the discs (D) (3), and alternately install the wave-plates (E) (2) and the discs (D) (2). Install the clutch end-plate (F) with the flat side down on the top disc.





19. Install the disc spring (A) in the 4th clutch drum (B) in the direction shown. Starting with the 4th clutch flat-plate, alternately install the flat-plates (C) (2) and the discs (D) (2), and alternately install the wave-plates (E) (2) and the discs (D) (2). Install the clutch end-plate (F) with the flat side down on the top disc.





20. Install the disc spring (A) in the 5th clutch drum (B) in the direction shown. Starting with the 5th clutch flat-plate, alternately install the flat-plates (C) (3) and the discs (D) (3), and alternately install the wave-plates (E) (2) and the discs (D) (2). Install the clutch end-plate (F) with the flat side down on the top disc.





21. Install the snap ring using a screwdriver to secure the clutch end-plate.