All Other Clutches

DISASSEMBLE





1. Remove the snap ring, then remove the clutch end plate, clutch discs and plates.





2. Remove the disc spring.

NOTE: Except 1st-hold clutch.





3. Install the special tools as shown.








CAUTION: If either end of the compressor attachment is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.





4. Compress the return spring.





5. Remove the snap ring. Then remove the special tools, spring retainer and return spring.





6. Wrap a shop rag around the clutch drum, and apply air pressure to the fluid passage to remove the 2nd, 3rd and 4th pistons. Place a finger tip on the other end while applying air pressure.
7. Install the secondary shaft with the old O-rings in the 1st/1st-hold/2nd clutch drum.





8. To remove the 1st clutch piston, apply air pressure to the secondary shaft fluid passage as shown.
9. Remove the 1st/1st-hold/2nd clutch drum from the secondary shaft.





10. To remove the 1st-hold clutch piston, apply air pressure to the 1st clutch piston fluid passage as shown.





11. To remove the 1st clutch back piston, apply air pressure to the outside of the 1st clutch drum as shown.

ASSEMBLE

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air.
- Blow out all passages.
- Lubricate all parts with ATF before assembly.





1. Inspect the check valve; if it's loose, replace the piston.





2. Install new O-rings on the piston.

NOTE: The 1st clutch piston has two O-rings inside the piston.





3. Install the piston in the clutch drum. Apply pressure and rotate to ensure proper seating.

NOTE: Lubricate the piston O-ring with ATF before installing.

CAUTION: Do not pinch the O-ring by installing the piston with too much force.





4. Install the return spring and spring retainer, and position the snap ring on the retainer.





5. Install the special tools as shown.








CAUTION: If either end of the compressor attachment is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged!





6. Compress the return spring.





7. Install the snap ring.
8. Remove the special tools.
9. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.

NOTE: The procedures in steps 10 through 15 are for the 1st-hold clutch. For the other clutches, skip these procedures and go to step 16.

10. Starting with a clutch plate, alternately install two clutch plates and two discs. install the 1st-hold clutch end plate, then install the top clutch disc.
11. Install the 1st clutch plate on the top clutch disc of the 1st-hold clutch so you can measure the 1st-hold clutch end plate-to-top disc clearance.





12. Measure the clearance between the 1st clutch plate and 1st-hold clutch top disc while pressing the clutch plate down.

NOTE: Take measurements in at least three places, and use the average as the actual clearance. Standard: 0.6 -1.0 mm (0.024 - 0.039 inch)





13. If the clearance is out of tolerance, select a new clutch end plate from the following table, then install it and recheck.

NOTE: If the thickest clutch end plate is installed, but the clearance is still over the standard, replace the clutch discs and clutch plates as a set.

14. After replacing the clutch end plate, make sure the clearance is within the tolerance.





15. Remove the 1st clutch plate, and install the 1st-hold clutch plate B on the top disc.





16. Install the disc spring.

NOTE: Install the disc spring in the direction shown.





17. Starting with a clutch plate, alternately install the clutch plates and discs. Install the clutch end plate with flat side toward the disc.

NOTE: Before installing the plates and discs, make sure the inside of the clutch drum is free of dirt or other foreign matter.





18. Install the snap ring.





19. Measure the clearance between the clutch end plate and top disc with a dial indicator. Zero the dial indicator with the clutch end plate lowered, and lift it up to the snap ring. The distance that the clutch end plate moves is the clearance between the clutch end plate and top disc.

NOTE: Take measurements in at least three places, and use the average as the actual clearance.





20. If the clearance is out of tolerance, select a new clutch end plate from the following table, then install it and recheck.

NOTE: If the thickest clutch end plate is installed, but the clearance is still over the standard, replace the clutch discs and clutch plates as a set.

21. After replacing the clutch end plate, make sure the clearance is within the tolerance.