Part 2
Clutch Disassembly (Continued)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 using a screwdriver.
2. Remove the clutch end-plate (A), the clutch discs (B) (6), the clutch wave-plates (C) (6), and the waved spring (D) from the 1st clutch drum (E).
3. Remove the clutch end-plate (A), the clutch discs (B) (4), the clutch flat-plates (C) (4), and the waved spring (D) from the 2nd clutch drum (E).
4. Remove the clutch end-plate (A), the clutch discs (B) (4), the clutch flat-plates (C) (4), and the waved spring (D) from the 4th clutch drum (E).
5. Remove the clutch end-plate (A), the clutch discs (B) (4), the clutch wave-plates (C) (4), and the waved spring (D) from the 3rd clutch drum (E).
6. Remove the clutch end-plate (A), the clutch discs (B) (4), the clutch wave-plates (C) (4), and the waved spring (D) from the 5th clutch drum (E).
7. Install the clutch spring compressor attachment and the clutch spring compressor bolt assembly.
8. Set the clutch spring compressor attachment (A) on the spring retainer (B) of the 1st clutch in such a way that it works on the clutch return spring (C).
9. Be sure the clutch spring compressor attachment (A) is adjusted to have full contact with the return spring retainer (B).
10. Check the placement of the clutch spring compressor attachment. 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.
11. Compress the return spring until the snap ring can be removed.
12. Remove the snap ring using snap ring pliers.
13. Remove the clutch spring compressor attachment and the clutch spring compressor bolt assembly.
14. Remove the snap ring (A), the spring retainer (B), and the return spring (C).
15. 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.
16. Remove the clutch piston (A), and remove the outer O-ring (B) and the inner O-ring (C) from the piston.
Clutch Inspection
1. Inspect the 4th and 5th 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. Check the oil seal (A) on the spring retainer of the 1st, 2nd, and 3rd clutches for wear, damage, and peeling.
5. If the oil seal is worn, damaged, or peeling, replace the spring retainer.
6. Inspect the clutch discs, the clutch plates, and the 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 (0.077 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 (wave-plates): 1.6 mm (0.063 in.)
2nd Clutch (flat-plates): 2.0 mm (0.079 in.)
3rd Clutch (wave-plates): 1.6 mm (0.063 in.)
4th Clutch (flat-plates): 1.6 mm (0.063 in.)
5th Clutch (wave-plates): 1.6 mm (0.063 in.)
7. 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.
8. 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.
9. 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 1st clutch wave-plate about 56-degrees or 67-degrees apart from the bottom while holding the wave-plate by its circumference, and rotate the 3rd and 5th clutch wave-plate about 60-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 top.
Standard: 0.07 - 0.20 mm (0.003 - 0.008 in.)
5. Rotate the 1st clutch wave-plate about 67-degrees or 56-degrees from the top, and rotate the 3rd and 5th clutch wave-plate about 60-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 the two values of the three measurements are within the standard, the wave-plate is OK. If the two values 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, discs, plates, and the end-plate for wear and damage, and inspect the clutch wave-plate phase difference, if necessary.
2. Install the clutch pistons in the clutch drums. Do not install the O-rings during inspection.
3. Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (6) and the discs (D) (6). Install the clutch end-plate (E) with the flat side down on the top disc.
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 the 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 the 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 wave-plate, alternately install the wave-plates (C) (4) and the 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 wave-plate, alternately install the wave-plates (C) (4) and the discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
8. Install the snap ring using 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 clutch compressor attachment on the end-plate (A).
12. For the 1st 3rd, and 5th clutches:
^ 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). 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 clutch compressor attachment 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.
Clearance between Clutch End-Plate and Top Disc 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 a 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
Special Tools Required
^ Clutch spring compressor attachment 07LAE-PX40100 or 07HAE-PL50101
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A
NOTE:
^ Hold the spring compressor attachment in a vise with soft jaws. Be careful not to damage the clutch drum.
^ Insert the spring retainer can be adjusted (center of tolerance) to prevent damaging the spring retainer oil seal.
1. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.
2. Install a new O-ring (A) in the 1st clutch piston (B), and install a new O-ring (C) on the clutch drums (D).
3. Install the clutch piston (A) in the clutch drum (B). Apply pressure and rotate to ensure proper seating. Lubricate the piston O-ring with ATF before installing. Do not pinch the O-ring by installing the piston with too much force.
4. Set the return spring (A) and the spring retainer (B), and position the snap ring (C) on the spring retainer.
5. Install the clutch spring compressor attachment and the clutch spring compressor bolt assembly.
6. Set the clutch spring compressor attachment (A) on the spring retainer (B) so that it compresses the clutch return spring (C).
7. Compress the return spring carefully until the snap ring can be installed. Check that the spring retainer (A) is properly installed on the clutch hub (B). If improperly installed, change the position of the spring compressor attachment and the spring retainer.
8. Install the snap ring with snap ring pliers.
9. Make sure the oil seal of the spring retainer (A) is properly installed on the clutch piston (B). If the oil seal was damaged or cracked, replace the spring retainer.
10. Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (6) and the discs (D) (6). Install the clutch end-plate (E) with the flat side down on the top disc.
11. Install the snap ring using a screwdriver to secure the clutch end-plate.
12. 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. Set the return spring (A) and the spring retainer (B), and position the snap ring (C) on the spring retainer.
5. Install the clutch spring compressor attachment and the clutch spring compressor bolt assembly.
6. Be sure the clutch spring compressor attachment (A) is adjusted to have full contact with the spring retainer (B).
7. Check the placement of the clutch spring compressor attachment. 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.
8. Compress the return spring until the snap ring can be installed.
9. Install the snap ring using snap ring pliers.
10. Remove the clutch spring compressor attachment and the clutch spring compressor bolt assembly.
11. 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 the 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 flat-plate, alternately install the flat-plates (C) (4) and the 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 wave-plate, alternately install the wave-plates (C) (4) and the discs (D) (4). Install the clutch end-plate (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 wave-plate, alternately install the wave-plates (C) (4) and the discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
15. Install the snap ring using a screwdriver to secure the clutch end-plate.
16. Check that the clutch piston moves by applying air pressure into fluid passage.