Part 2
Clutch Inspection1. Inspect the clutch pistons and 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, clutch plates, and clutch end-plate for wear, damage, and discoloration.
Clutch Discs Standard Thickness:
1st clutch: 1.94 mm (0.076 in.)
2nd clutch: 1.96 mm 10.077 in.)
3rd clutch: 1.94 mm (0.076 in.)
4th clutch: 1.96 mm (0.077 in.)
5th clutch: 1.94 mm (0.076 in.)
Clutch Plates Standard Thickness:
1st clutch (waved-plates): 1.6 mm (0.063 in.)
2nd clutch (flat-plates): 2.0 mm (0.079 in.)
3rd clutch (waved-plates): 1.6 mm (0.063 in.)
4th clutch (flat-plates): 1.6 mm (0.063 in.)
5th clutch (waved-plates): 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 clutch end-plate to-top disc clearance,
7. If any flat-plate is worn, damaged, or discolored, replace them as a set. If the clutch flat-plates are replaced, inspect the clutch end-plate-to-top disc clearance.
8. If any waved-plate is worn, damaged, or discolored, replace the damaged plate with a new plate, and inspect the other waved-plates for a phase difference. If the clutch waved-plate is replaced, inspect the clutch end-plate-to-top disc clearance.
9. If the clutch end-plate is worn, damaged, or discolored, inspect the clutch end-plate-to-top disc clearance, then replace the clutch end-plate.
Clutch Waved-plate Phase Difference Inspection
1. Place the clutch waved-plate (A) on a surface plate, and set a dial indicator (B) on the waved-plate.
2. Find the bottom (C) of a phase difference of the waved-plate, zero the dial indicator and make a reference mark on the bottom of the waved-plate.
3. Rotate the 1st clutch waved-plate about 56° or 67° apart from the bottom while holding the waved-plate by its circumference, and rotate the 3rd and 5th clutch waved-plate about 60° apart from the bottom while holding the waved plate by its circumference, The dial indicator should be at the top (D) of a phase difference. Do not rotate the waved-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 waved-plate between the bottom and top.
Standard: 0.07 - 0.20 mm (0.003 - 0.008 in.)
5. Rotate the 1st clutch waved-plate about 67° or 56° from the top, and rotate the 3rd and 5th clutch waved-plate about 60°. 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 waved-plate by following steps 3 thru 5.
7. If the two values of the three measurements are within the standard, the waved plate is OK. If the two values of the three measurements are out of the standard, replace the waved-plate.
Clutch Clearance Inspection
Special Tools Required
Clutch compressor attachment 07ZAE-PRP0100
1. Inspect the clutch piston, discs, plates, and endplate for wear and damage, and inspect the clutch waved-plate phase difference, if necessary.
2. Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch waved-plate, alternately install the waved-plates (C) (6) and discs (D) (6). Install the clutch end-plate (E) with the flat side down on the top disc.
3. Install the clutch pistons in the 2nd, 3rd, 4th, and 5th clutch drums. Do not install the O-rings during inspection.
4. Install the waved spring (A) in the 2nd clutch drum (B). Starting with the clutch flat-plate, alternately install the flat-plates (C) (4) and discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
5. Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch flat-plate, alternately install the flat-plates (C) (4) and discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
6. Install the waved spring (A) in the 3rd 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.
7. 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.
8. Install the snap ring with a screwdriver to secure the clutch end-plate.
9. Set a dial indicator (A) on the clutch end-plate (B).
10. Zero the dial indicator with the clutch end-plate lifted up to the snap ring (C).
11. Release the clutch end-plate to lower the clutch end-plate, then put the special tool on the end-plate (A).
12. For the 1st, 3rd, and 5th clutches:
^ Press the special tool down with 150 - 160 N (15 - 16 kgf, 33 - 35 lbf) (B) using a force gauge, and read the dial indicator (C). 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.
13. For 2nd and 4th clutches:
Press the special tool down with 39 N (4 kgf, 9 lbf) (B) using a force gauge, and read the dial indicator (C). 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:
1st clutch: 1.62 - 1.82 mm (0.064 - 0.072 in.)
2nd clutch: 0.7 - 0.9 mm (0.028 - 0.035 in.)
3rd clutch: 0.93 - 1.13 mm (0.037 - 0.044 in.)
4th clutch: 0.7 - 0.9 mm (0.028 - 0.035 in.)
5th clutch: 0.93 - 1.13 mm (0.037 - 0.044 in.)
14. If the clearance of the 1st, 3rd, or 5th clutch is out of the service limit, select a new clutch end-plate from the following table.
15. If the clearance of the 2nd or 4th clutch is out of the service limit, remove the clutch end-plate and check the clutch end-plate mark. Select a new clutch end-plate from the following tables by the mark on the old clutch end-plate; use the AC-AL Plates table with the old clutch end-plate is marked with between AC and AL, and use the AM-AV Plates table with the old clutch end-plate is marked with between AM and AV.
16. 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 discs and plates.
1st Clutch Reassembly
1. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.
2. Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch waved-plate, alternately install the waved-plates (C) (6) and discs (D) (6). Install the clutch end-plate (E) with the flat side down on the top disc.
3. Install the snap ring with a screwdriver to secure the clutch end-plate.
4. Check that the clutch piston moves by applying air pressure into fluid passage.
2nd, 3rd, 4th, and 5th 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 clutch piston (B).
3. 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.
4. Install the return spring (A) and spring retainer (B), and position the snap ring (C) on the spring retainer.
5. Install the special tools.
6. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B).
7. If either end of the special tool is set over an area of the spring retainer that is unsupported by the return spring, the retainer may be damaged.
8. Compress the return spring until the snap ring can be installed.
9. Install the snap ring with the snap ring pliers.
10. Remove the special tools.
11. Install the waved spring (A) in the 2nd clutch drum (B). Starting with the clutch flatplate, alternately install the flat-plates (C) (4) and discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
12. Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch flatplate, alternately install the flat-plates (C) (4) and discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
13. Install the waved spring (A) in the 3rd clutch drum (B). Starting with the clutch waved plate, alternately install the waved-plates (C) (4) and discs (D) (4). Install the clutch endplate (E) with the flat side down on the top disc.
14. 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. Check that the clutch piston moves by applying air pressure into fluid passage.