Reassembly

U250E AUTOMATIC TRANSAXLE: FORWARD CLUTCH: REASSEMBLY

REASSEMBLY

1. INSTALL INPUT SHAFT OIL SEAL RING





(a) Compress a new input shaft oil seal ring from both sides to adjust dimension A.
Dimension A:
5 mm (0.197 in.)
(b) Coat the oil seal ring with ATF and install it to the input shaft.
NOTICE: Do not expand the gap of the oil seal ring too much. Securely engage the hooks.

2. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY





(a) Coat the forward clutch piston with ATF, and install it to the input shaft.
NOTICE: Be careful not to damage the lip seal of the forward clutch piston.

3. INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY





(a) Install the return spring to the input shaft.
NOTICE: After installing the spring sub-assembly, check all of the springs are fitted in the piston correctly.

(b) Coat the clutch balancer with ATF.





(c) Install the clutch balancer to the input shaft.
NOTICE:
- Be careful not to damage the lip seal of the forward clutch balancer.
- Install the clutch balancer carefully not to have a pinching or any other defects at the sealing lip.
- Apply enough ATF to the sealing lip prior to installation.





(d) Place SST on the clutch balancer, and compress the clutch balancer with a press.
SST: 09387-00020
(e) Install the snap ring with a snap ring expander.
NOTICE:
- Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove. This prevents the spring seat from being deformed.
- Do not expand the snap ring excessively.





(f) Position the end gap of the snap ring in the piston as shown in the illustration.
NOTICE: The end gap of the snap ring should not be aligned with any of the stoppers.

4. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC
(a) Coat the 5 discs with ATF.





(b) Install the 5 plates, 5 discs, and flange to the input shaft.
NOTICE: Be careful about the order of discs, plates, and flange.





(c) Using a screwdriver, install the snap ring.
(d) Check that the end gap of the snap ring is not aligned with one of the cutouts.
NOTICE: The snap ring should be securely engaged in the groove of the drum.

5. INSPECT PACK CLEARANCE OF FORWARD CLUTCH Forward Clutch
6. INSPECT FORWARD MULTIPLE CLUTCH DISC Forward Clutch