A/T Clutch Clearance Inspection

A/T Clutch Clearance Inspection

Special Tools Required

- Clutch compressor attachment 07ZAE-PRP0100
1. Inspect the clutch piston, the clutch discs, the clutch plates, and the end-plate for wear and damage, A/T Clutch Inspection and inspect the clutch wave-plate phase difference, A/T Clutch Wave-Plate Phase Difference Inspection 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 toward 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 toward 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 toward 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 toward 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 toward 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 N (15 kgf, 33 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 the top disc (E). Take measurements in at least three places, and use the average as the actual clearance.

13. For the 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 the top disc (E). Take measurements in at least three places, and use the average as the actual clearance.










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.

1ST, 3RD, and 5TH CLUTCH END-PLATES










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.

2ND and 4TH CLUTCH END-PLATES AC-AL Plates





AM-AV Plates





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.