CLUTCH DRUM AND INPUT SHAFT ASSEMBLY > REASSEMBLY

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1. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY


D028816E01

  1. Coat 2 new O-rings with ATF, and install them in the direct clutch piston.



    D028517E01

  1. Install the No. 2 clutch balancer and direct clutch return spring to the direct clutch piston sub-assembly.



    D028516E01

  1. Coat a new O-ring with ATF, and install them on the clutch drum sub-assembly.

  1. Be careful not to damage the O-rings. Press in the direct clutch piston into the clutch drum with both hands.



    D028514E05

  1. Place SST on the direct clutch piston, and compress the return spring with a press.

    SST
    09320-89010  
    09350-30020   (09350-07070)

  1. Install the snap ring with a snap ring expander.

    NOTICE:
    1. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
    2. Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.
    3. Do not expand the snap ring excessively.



    D028536E03

  1. Set the end gap of the snap ring in the piston as shown in the illustration.



2. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY


D028513E01

  1. Coat a new O-ring with ATF, and install it on the clutch drum sub-assembly.



    D028512E01

  1. Coat a new O-ring with ATF, and install it on the reverse clutch piston sub-assembly.



    D028511E01

  1. Be careful not to damage the O-ring. Press in the clutch drum sub-assembly into the reverse clutch piston with both hands.



3. INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY


D028510E01

  1. Coat a new O-ring with ATF, and install it on the reverse clutch piston sub-assembly.

  1. Install the reverse clutch return spring onto the reverse clutch piston sub-assembly.



4. INSTALL NO. 3 CLUTCH BALANCER


D028509E03

  1. Place SST on the No. 3 clutch balancer, and compress the clutch balancer with a press.

    SST
    09387-00070  
    09350-30020   (09350-07070)

  1. Install the snap ring with a snap ring expander.

  1. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

    NOTICE:
    1. Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.
    2. Do not expand the snap ring excessively.



    D028534E02

  1. Set the end gap of the snap ring in the piston as shown in the illustration.



5. INSTALL DIRECT CLUTCH DISK


D028508E02

  1. Install the reverse clutch flange, 6 plates and 5 discs on the clutch drum sub-assembly.

    Install in order:
    P - P - D - P - D - P - D - P - D - P - D - F

    HINT:
    P = Plate, D = Disc, F = Flange



    D028507E01

  1. Using a screwdriver, install the 2 hole snap rings on the clutch drum sub-assembly.



6. INSPECT PACK CLEARANCE OF DIRECT CLUTCH


D029841E02

  1. Using a dial gauge, measure the moving distance (distance A) of the clutch flange at both ends across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.

    Pack clearance:
    0.5 to 0.8 mm (0.020 to 0.031 in.)

    NOTICE:
    Install a selective flange (3.4 mm (0.134 in.)) when measuring the moving distance (shaded area in the illustration.)

    HINT:
    Flange moving distance A = 0.26 to 1.14 mm (0.010 to 0.045 in.)
    Pack clearance = Flange moving distance A - 0.05 mm (0.002 in.)

  1. If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

    Flange thickness:
    No.
    		Thickness
    		No.
    		Thickness
    0
    		3.0 mm (0.118 in.)
    		5
    		3.5 mm (0.138 in.)
    1
    		3.1 mm (0.122 in.)
    		6
    		3.6 mm (0.142 in.)
    2
    		3.2 mm (0.126 in.)
    		7
    		3.7 mm (0.146 in.)
    3
    		3.3 mm (0.130 in.)
    		8
    		3.8 mm (0.150 in.)
    4
    		3.4 mm (0.134 in.)
    		-
    		-



7. INSTALL REVERSE CLUTCH FLANGE


D028506E01

  1. Install the reverse clutch flange to the clutch drum sub-assembly.



8. INSTALL REVERSE CLUTCH REACTION SLEEVE


D029843E01

  1. Install the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates to the reverse clutch hub.

  1. Using a screwdriver, install the hole snap ring.



9. INSPECT PACK CLEARANCE OF REVERSE CLUTCH


  1. Using a dial gauge, measure the reverse clutch piston stroke (distance A) and the moving distance (distance B) of the reverse flange at the both ends across a diameter while blowing air (392 kPa, 4 kgf/cm2, 57 psi) from the oil hole as shown in the illustration, and calculate the average.

    Pack clearance:
    0.5 to 0.8 mm (0.020 to 0.031 in.)

    NOTICE:
    Install a selective flange (3.3 mm (0.130 in.)) when measuring the moving distance (shaded area in the illustration.)

    HINT:
    Piston stroke A = 1.05 to 2.15 mm (0.041 to 0.085 in.)
    Flange moving distance B = 0.72 to 1.08 mm (0.029 to 0.043 in.)
    Pack clearance = Piston stroke A to Flange moving distance B to 0.06 mm (0.002 in.)



    D028538E02

  1. If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

    Flange thickness:
    No.
    		Thickness
    		No.
    		Thickness
    0
    		2.8 mm (0.110 in.)
    		6
    		3.4 mm (0.134 in.)
    1
    		2.9 mm (0.114 in.)
    		7
    		3.5 mm (0.138 in.)
    2
    		3.0 mm (0.118 in.)
    		8
    		3.6 mm (0.142 in.)
    3
    		3.1 mm (0.122 in.)
    		9
    		3.7 mm (0.146 in.)
    4
    		3.2 mm (0.126 in.)
    		A
    		3.8 mm (0.150 in.)
    5
    		3.3 mm (0.130 in.)

    		-



10. REMOVE REVERSE CLUTCH REACTION SLEEVE


D029844E01

  1. Using a screwdriver, remove the snap ring from the clutch drum assembly.



    D029843E01

  1. Remove the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates from the reverse clutch hub sub-assembly.



11. INSTALL FORWARD CLUTCH PISTON


D028525E01

  1. Coat 2 new O-rings with ATF, and install them on the No. 1 forward clutch piston.



12. INSTALL NO. 1 CLUTCH BALANCER


D028523E01

  1. Coat a new O-ring with ATF and install it on the clutch balancer.



    D028522E01

  1. Install the No. 1 clutch balancer and forward clutch return spring sub-assembly.

    NOTICE:
    Be careful not to damage the O-ring.



    D028521E02

  1. Place SST on the No. 1 clutch balancer, and compress the return spring with a press.

    SST
    09350-30020   (09350-07040, 09350-07070)

  1. Install the snap ring with a snap ring expander.

  1. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

    NOTICE:
    1. Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.
    2. Do not expand the snap ring excessively.



    D028535E02

  1. Set the end gap of the snap ring in the piston as shown in the illustration.



13. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC


D028520E02

  1. Install the 2 flanges, 6 discs and 5 plates to the input shaft assembly.



    D028519E01

  1. Install in order:
    F- D - P - D - P - D - P - D - P - D - P - D - F

    HINT:
    P = Plate, D = Disc, F = Flange

    Using a screwdriver, install the hole snap ring.



14. INSTALL INPUT SHAFT OIL SEAL RING


D029677E01

  1. Coat the 3 oil seal rings with ATF.

  1. Squeeze the ends of the 3 oil seal rings together, and then install them to the starter shaft groove.

    NOTICE:
    Do not over-spread the ring ends.

    HINT:
    After installing the oil seal rings, check that they rotate smoothly.



15. INSPECT PACK CLEARANCE OF FORWARD CLUTCH


D028537E02

  1. Using a dial gauge, measure the moving distance (distance A) of the clutch flange at boths end across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.

    Pack clearance:
    0.6 to 0.9 mm (0.024 to 0.354 in.)

    NOTICE:
    Install a selective flange (3.4 mm (0.134 in.)) when measuring the moving distance (shaded area in the illustration.)

    HINT:
    Flange moving distance A = 0.26 to 1.36 mm (0.010 to 0.054 in.)
    Pack clearance = Flange moving distance A to 0.01 mm (0.0003 in.)

  1. If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

    Flange thickness:
    No.
    		Thickness
    		No.
    		Thickness
    0
    		3.0 mm (0.118 in.)
    		6
    		3.6 mm (0.142 in.)
    1
    		3.1 mm (0.122 in.)
    		7
    		3.7 mm (0.146 in.)
    2
    		3.2 mm (0.126 in.)
    		8
    		3.8 mm (0.150 in.)
    3
    		3.3 mm (0.130 in.)
    		9
    		3.9 mm (0.154 in.)
    4
    		3.4 mm (0.134 in.)
    		A
    		4.0 mm (0.158 in.)
    5
    		3.5 mm (0.138 in.)

    		-



16. INSTALL INPUT SHAFT ASSEMBLY


D028505E01

  1. Install the input shaft assembly to the clutch drum.



    D028504E01

  1. Install the thrust needle roller bearing to the clutch drum assembly.

    Thrust needle roller bearing diameter:
    Item
    		Inside
    		Outside
    Thrust needle roller bearing
    		21.3 mm (0.839 in.)
    		41.1 mm (1.618 in.)



17. INSTALL MULTIPLE DISC CLUTCH HUB


D028503E02

  1. Install the No. 2 thrust bearing race and input shaft thrust bearing race rear to the multiple disc clutch hub.

    Bearing and race diameter:
    Item
    		Inside
    		Outside
    Thrust bearing race No. 2
    		38.4 mm (1.512 in.)
    		63.0 mm (2.480 in.)
    Input shaft bearing race RR
    		22.6 mm (0.890 in.)
    		60.0 mm (2.362 in.)



    D028502E01

  1. Install the multiple disc clutch hub to the clutch drum assembly.



18. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY


D028500E04

  1. Install the 2 thrust needle roller bearings to the forward clutch hub sub-assembly.

    Bearing and race diameter:
    Item
    		Inside
    		Outside
    Bearing A
    		42.5 mm (1.673 in.)
    		61.2 mm (2.409 in.)
    Bearing B
    		33.3 mm (1.311 in.)
    		56.6 mm (2.228 in.)



    D028001E01

  1. Install the forward clutch hub sub-assembly to the clutch drum assembly.



19. INSTALL REAR CLUTCH DISC


D027999E05

  1. Install the clutch cushion plate, reverse clutch flange, 4 plates and 5 discs to the reverse clutch hub.

    Install in order:
    D - P - D - P - D - P - D - P - D - F

    HINT:
    P = Plate, D = Disc, F = Flange



20. INSTALL REVERSE CLUTCH REACTION SLEEVE


D027998E01

  1. Install the reverse clutch reaction sleeve to the reverse clutch hub.



21. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY


D027997E01

  1. Install the reverse clutch hub sub-assembly, reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates to the clutch drum assembly.



    D027996E01

  1. Using a screwdriver, install the snap ring on the clutch drum and input shaft assembly.