Part 2
Clutch Clearance InspectionSpecial Tools Required
Clutch compressor attachment 07ZAE-PRP0100
1. Inspect the clutch piston, discs, plates, and end plate for wear and damage, and inspect clutch waved-plate phase difference, if necessary.
2. Install the clutch piston in the clutch drum. Do not install the O-rings during inspection.
3. 2003-2005-model 1st clutch:
Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plate (C) (5) and discs (D) (5). Install the clutch-end-plate (E) with the flat side down on the top disc.
4. 2003-2005-model 2nd clutch:
Install the waved spring (A) in the 2nd clutch drum (B). Install the 4.0 mm-thick plate (C) with the shear droop side (D) toward the inside of the drum, clutch disc (E), and 2.0 mm-thick flat-plate (F), then starting with the disc, alternately install the discs (G) (4) and waved-plates (H) (3). Install the clutch end-plate (I) with the flat side down on the top disc.
5. 2003-2005-model 3rd clutch:
Install the waved spring (A) in the 3rd clutch drum (B). Install the clutch flat-plate (C), clutch disc (D), and clutch flat-plate (E). Starting with the clutch disc, alternately install the clutch discs (F) (4) and clutch waved-plates (G) (3). Install the clutch-end plate (H) with the flat side down on the top disc.
6. 2003-2004-model 4th clutch:
Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plate (C) (3) and discs (D) (3). Install the clutch end plate (E) with the flat side down on the top disc.
7. 2003-2004-model 5th clutch:
Install the waved spring (A) in the 5th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plate (C) (3) and discs (D) (3). Install the clutch end plate (E) with the flat side down on the top disc.
8. 2005-model 4th clutch:
Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plate (C) (4) and discs (D) (4). Install the clutch end plate (E) with the flat side down on the top disc.
9. 2005-model 5th clutch:
Install the waved spring (A) in the 5th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plate, (C) (4) and discs (D) (4). Install the clutch end plate (E) with the flat side down on the top disc.
10. 2006-2007-model 1st clutch:
Install the waved spring (A) in the 1st clutch drum (B). Install the clutch flat-plate (C), then starting with the clutch disc, alternately install the discs (D) (5) and waved-plates (E) (4). Install the clutch-end plate (F) with the flat side down on the top disc.
11. 2006-2007-model 2nd clutch:
Install the waved spring (A) in the 2nd clutch drum (B). Install the clutch flat-plate (C), then starting with the clutch disc, alternately install the discs (D) (6) and clutch waved-plates (E) (5). Install the clutch-end-plate (F) with the flat side down on the top disc.
12. 2006-2007-model 3rd clutch:
Install the waved spring (A) in the 3rd clutch drum (B). Install the clutch flat-plate (C), then starting with the clutch disc, alternately install the discs (D) (6) and waved-plates (E) (5). Install the clutch-end plate (F) with the flat side down on the top disc.
13. 2006-2007-model 4th clutch:
Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch waved-plate, alternately install the waved-plates (C) (4) and discs (D) (4). Install the clutch-end-plate (E) with the flat side down on the top disc.
14. 2006-2007-model 5th clutch:
Install the waved spring (A) in the 5th clutch drum (B). Starting with the clutch waved-plate, alternately install the waved-plates (C) (4) and discs (D) (4). Install the clutch-end-plate (E) with the flat side down on the top disc.
15. Install the snap ring with a screwdriver to secure the clutch-end-plate.
16. Set a dial indicator (A) on the clutch-end-plate (B).
17. Zero the dial indicator with the clutch-end-plate lifted up to the snap ring (C).
18. Release the clutch-end-plate to lower the clutch end-plate, then put the special tool on the end-plate (A).
19. Press the special tool down with 150 - 160 N (15 - 16 kgf, 33 - 35 lbs.) (B) using a force gauge, and read the dial indicator (C).
20. The dial indicator reads the clearance (D) between the clutch-end-plate and top disc (E)., Take measurements in at least three places, and use the average as the actual clearance.
Clutch-End-Plate-to-Top Disc Clearance
Service Limit
2003-2004 Models
1st clutch: 1.28 - 1.48 mm (0.050 - 0.058 inch)
2nd clutch: 0.88 - 1.08 mm (0.035 - 0.043 inch)
3rd clutch: 0.93 - 1.13 mm (0.037 - 0.044 inch)
4th clutch: 0.73 - 0.93 mm (0.029 - 0.037 inch)
5th clutch: 0.73 - 0.93 mm (0.029 - 0.037 inch)
2005 Model
1st clutch: 1.28 - 1.48 mm (0.050 - 0.058 inch)
2nd clutch: 0.88 - 1.08 mm (0.035 - 0.043 inch)
3rd clutch: 0.93 - 1.13 mm (0.037 - 0.044 inch)
4th clutch: 0.93 - 1.13 mm (0.037 - 0.044 inch)
5th clutch: 0.93 - 1.13 mm (0.037 - 0.044 inch)
2006-2007 Model
1st clutch: 1.38 - 1.58 mm (0.054 - 0.062 inch)
2nd clutch: 1.18 - 1.38 mm (0.046 - 0.054 inch)
3rd clutch: 1.23 - 1.43 mm (0.048 - 0.056 inch)
4th clutch: 0.93 - 1.13 mm (0.037 - 0.044 inch)
5th clutch: 0.93 - 1.13 mm (0.037 - 0.044 inch)
1ST, 2ND, And 3RD CLUTCH END PLATES - 2003-2005 Models:
1ST And 2ND CLUTCH END PLATES - 2005 Model:
3RD CLUTCH END PLATES - 2006 Model:
4TH And 5TH CLUTCH END PLATES - All Models:
21. If the clearance is out of the service limit, select a new clutch-end-plate from the following table.
22. Install the new clutch-end-plate, and recheck the clearance. If the thickest clutch-end-plate is installed, but the clearance is still over the service limit, replace the clutch disc and 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 the new O-rings (A) on the 4th and 5th clutch piston (B).
3. Install the new O-ring (A) in the 1st, 2nd, and 3rd clutch pistons (B), and install the new O-ring (C) on the clutch drums (D).
4. Install the clutch piston (A) in the clutch drum (B) while applying pressure and rotating to ensure proper seating. Do not pinch the O-ring.
5. Install the return spring (A) and spring retainer (B), and position the snap ring (C) on the retainer.
6. Install the special tools.
7. Set the special tool (A) on the spring retainer (B) of the 1st, 2nd, and 3rd clutches so the special tool works on the clutch return spring (C).
8. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 4th and 5th clutches.
9. If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.
10. Compress the return spring.
11. Install the snap ring with snap ring pliers.
12. Remove the special tools.
13. 2003-2005-model 1st clutch:
Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plate (C) (5) and discs (D) (5). Install the clutch-end-plate (E) with the flat side down on the top disc.
14. 2003-2005-model 2nd clutch:
Install the waved spring (A) in the 2nd clutch drum (B). install the 4.0 mm-thick plate (C) with the shear droop side (D) toward the inside of the drum, clutch disc (E), and 2.0 mm-thick flat-plate (F), then starting with the disc, alternately install the discs (G) (4) and waved-plates (H) (3). Install the clutch end-plate (I) with the flat side down on the top disc.
15. 2003-2005-model 3rd clutch:
Install the waved spring (A) in the 3rd clutch drum (B). Install the clutch flat plate (C), clutch disc (D), and clutch flat-plate (E). Starting with the clutch disc, alternately install the clutch discs (F) (4) and clutch waved-plates (G) (3). Install the clutch-end plate (H) with the flat side down on the top disc.
16. 2003-2004-model 4th clutch:
Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plate (C) (3) and discs (D) (3). Install the clutch end plate (E) with the flat side down on the top disc.
17. 2003-2004-model 5th clutch:
Install the waved spring (A) in the 5th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (3) and discs (D) (3). Install the clutch end plate (E) with the flat side down on the top disc.
18. 2005-model 4th clutch:
Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch waved-plate, alternately install the waved-plates (C) (4) and discs (D) (4). Install the clutch-end-plate late (E) with the flat side down on the top disc.
19. 2005-model 5th clutch:
Install the waved spring (A) in the 5th clutch drum (B). Starting with the clutch waved-plate, alternately install the waved-plates (C) (4) and discs (D) (4). Install the clutch-end-plate (E) with the flat side down on the top disc.
20. 2006-2007-model 1st clutch:
Install the waved spring (A) in the 1st clutch drum (B). Install the clutch flat-plate (C), then starting with the clutch disc, alternately install the discs (D) (5) and waved-plates (E) (4). Install the clutch-end plate (F) with the flat side down on the top disc.
21. 2006-2007-model 2nd clutch:
Install the waved spring (A) in the 2nd clutch drum (B). Install the clutch flat-plate (C), then starting with the clutch disc, alternately install the discs (D) (6) and clutch waved-plates (E) (5). Install the clutch-end-plate (F) with the flat side down on the top disc.
22. 2006-2007-model 3rd clutch:
Install the waved spring (A) in the 3rd clutch drum (B). Install the clutch flat-plate (C), then starting with the clutch disc, alternately install the discs (D) (6) and waved-plates (E) (5). Install the clutch-end plate (F) with the flat side down on the top disc.
23. 2006-2007-model 4th clutch:
Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch waved-plate, alternately install the waved-plates (C) (4) and discs (D) (4). Install the clutch-end-plate (E) with the flat side down on the top disc.
24. 2006-2007-model 5th clutch:
Install the waved spring (A) in the 5th clutch drum (B). Starting with the clutch waved-plate, alternately install the waved-plates (C) (4) and discs (D) (4). Install the clutch-end-plate (E) with the flat side down on the top disc.
25. Install the snap ring with a screwdriver to secure the clutch-end-plate.
26. Check that the clutch piston moves by applying air pressure into fluid passage.