Part 2

Clutch Inspection





1. 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. Check the oil seal (A) on the spring retainer of the 1st, 2nd, and 3rd clutches for wear, damaged, and peeling.
6. If the oil seal is worn, damaged, or peeling, replace the spring retainer.
7. Inspect the clutch discs, clutch plates, and clutch end-plate for wear, damage, and discoloration.

Clutch Discs for All Models
Standard Thickness: 1.94 mm (0.076 inch)

Clutch Plates
Standard Thickness

2004-2005 Models
1st clutch
Flat-plates: 1.6 mm (0.063 inch)
2nd clutch
Waved-plates, 2.0 mm (0.079 inch)
Flat-plate: 2.0 mm 10.079 inch)
4.0 mm-thick plate: 4.0 mm (0.157 inch)
3rd clutch
Flat-plates: 1.6 mm (0.063 inch)
4th clutch
Waved-plates: 2.0 mm (0.079 inch)
5th clutch
Waved-plates: 2.0 mm (0.079 inch)

2006 Model
1st clutch
Flat-plates: 1.6 mm (0.063 inch)
2nd clutch
Waved-plates: 2.0 mm (0.079 inch)
Rat-plate: 2.0 mm (0.079 inch)
3rd clutch
Flat-plates: 1.6 mm (0.063 inch)
4th clutch
Waved-plates: 2.0 mm (0.079 inch)
5th clutch
Waved-plates: 2.0 mm (0.079 inch)

8. 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.
9. If any 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 plate is replaced, inspect the clutch end-plate-to-top-disc clearance.
10. 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 (D) 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 waved-plate about 60-degrees apart from the bottom while holding the waved-plate by its circumference. The dial indicator should be at the top (E) of a phase difference. Do not rotate the waved-plate while holding its surface, always rotate it with holding its circumference.
4. Read the dial indicator. The dial indicator reads the phase difference (C) of the waved-plate between bottom and top.
Standard Phase Difference
2nd clutch: 0.10 - 0.20 mm
4th clutch: 0.07 - 0.20 mm
5th clutch: 0.07 - 0.20 mm

5. Rotate the waved-plate about 60-degrees. The dial indicator should be at the bottom of a phase difference (F and H), and zero the dial indicator.
6. Measure the phase difference at the other two tops (G 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 end plate for wear and damage, and inspect clutch waved-plate phase difference, if necessary.





2. Install the clutch piston in the clutch drum. Do not install the O-rings during inspection.





3. 1st clutch: Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch plate, alternately install the clutch plate (C) (5) and discs (D) (5), then install the clutch end-plate (E) with the flat side toward the disc.





4. 2004-2005-models 2nd clutch: Install the waved spring (A) in the 2nd clutch drum (B). Install the 4.0 mm-thick plate (C) with the shear droop side (D) toward the inside of the drum, clutch disc (E), and 2.0 mm-thick flat-plate (F), then starting with the disc, alternately install the discs (G) (4) and waved-plates (H) (3), then install the clutch end-plate (I) with the flat side toward the disc.





5. 2006-model 2nd clutch: Install the waved spring (A) In the 2nd clutch drum (B). Install the clutch flat-plate (C), then starting with the clutch disc, alternately install the discs (D) (6) and clutch waved-plates (E) (5). Install the clutch end-plate (F) with the flat side down on the top disc.





6. 2004-2005-models 3rd clutch: Install the waved spring (A) in the 3rd clutch drum (B). Starting with the clutch plate, alternately install the clutch plate (C) (5) and discs (D) (5), then install the clutch end-plate (E) with the flat side toward the disc.





7. 2006-model 3rd clutch: Install the waved spring (A) in the 3rd clutch drum (B). Install the clutch flat-plates (C) (6), then starting with the clutch disc, alternately install the discs (D) (6). Install the clutch end-plate (E) with the flat side down on the top disc.





8. 2004-2005-models 4th clutch: Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (4) and discs (D) (4), then install the clutch end-plate (E) with the flat side toward the disc.





9. 2006-model 4th clutch: Install the waved spring (A) in the 4th 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.





10. 2004-2005-model 5th clutch: Install the waved spring (A) in the 5th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (4) and discs (D) (4), then install the clutch end-plate (E) with the flat side toward the disc.





11. 2006-model 5th clutch: 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.





12. Install the snap ring with a screwdriver to secure the clutch end-plate.





13. Set a dial indicator (A) on the clutch end-plate (B).
14. Zero the dial indicator with the clutch end-plate lifted up to the snap ring (C).





15. Release the clutch end plate to lower the clutch end-plate, then put the special tool on the end-plate (A).
16. For 2nd, 4th, and 5th clutches: Press the special tool down with 150 - 160 N (15 - 16 kgf, 33 - 35 lbs.) using a force gauge, and read the dial indicator (B).
17. For 1st and 3rd clutches: Press the special tool down with 39 N (4.0 kgf, 9 lbs.) using a force gauge, and read the dial indicator (B).
18. The dial indicator reads the clearance (C) between the clutch end plate and top disc (D). Take measurements in at least three places, and use average as the actual clearance.

Clutch-End-Plate-to-Top-Disc-Clearance Service
Limit 2004-2005 Models
1st clutch: 0.82-1.02 mm (0.032-0.040 inch)
2nd clutch: 0.88-1.08 mm (0.035-0.043 inch)
3rd clutch: 0.82-1.02 mm (0.032-0.040 inch)
4th clutch: 0.93-1.13 mm (0.037-0.044 inch)
5th clutch: 0.93-1.13 mm (0.037-0.044 inch)

2006 Model
1st clutch: 0.82-1.02 mm (0.032-0.040 inch)
2nd clutch: 1.18-1.38 mm (0.046-0.054 inch)
3rd clutch: 1.00-1.11 mm (0.039-0.044 inch)
4th clutch: 0.93-1.13 mm (0.037-0.044 inch)
5th clutch: 0.93-1.13 mm (0.037-0.044 inch)























19. If the clearance is out of the service limit, select a new clutch end-plate from the table.
20. 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.

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 the new O-rings (A) on the 4th and 5th clutch piston (B).





3. Install the new O-ring (A) in the 1st, 2nd, and 3rd clutch pistons (B), and install the new O-ring (C) on the clutch drums (D).





4. 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 to much force.





5. Install the return spring (A) and spring retainer (B), and position the snap ring (C) on the retainer.





6. Install the special tools.





7. Set the special tool (A) on the spring retainer (B) of the 1st, 2nd, and 3rd clutches in such a way that the special tool compresses the clutch return spring (C).





8. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 4th and 5th clutches.





9. If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.





10. Compress the return spring.





11. Install the snap ring with snap ring pliers.
12. Remove the special tools.





13. 1st clutch: Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch plate, alternately install the clutch plates (C) (5) and discs (D) (5), then install the clutch end-plate (E) with the flat side toward the disc.





14. 2004-2005-models 2nd clutch: Install the waved spring (A) in the 2nd clutch drum (B). Install the 4.0 mm-thick plate (C) with the shear droop side (D) toward the inside of the drum, clutch disc (E), and 2.0 mm-thick flat-plate (F), then starting with the disc, alternately install the discs (G) (4) and waved-plates (H) (3), then install the clutch end-plate (I) with the flat side toward the disc.





15. 2006-model 2nd clutch: Install the waved spring (A) in the 2nd clutch drum (B). Install the clutch flat-plate (C), then starting with the clutch disc, alternately install the discs (D) (6) and clutch waved-plates (E) (5). Install the clutch end-plate (F) with the flat side down on the top disc.





16. 2004-2005-models 3rd clutch: Install the waved spring (A) In the 3rd clutch drum (B). Starting with the clutch plate, alternately install the clutch plates (C) (5) and discs (D) (5), then install the clutch end-plate (E) with the flat side toward the disc.





17. 2006-model 3rd clutch: Install the waved spring (A) in the 3rd clutch drum (B). Install the clutch flat-plates (C) (6), then starting with the clutch disc, alternately install the discs (D) (6). Install the clutch end-plate (E) with the flat side down on the top disc.





18. 2004-2005-models 4th clutch: Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (4) and discs (D) (4), then install the clutch end-plate (E) with the flat side toward the disc.





19. 2006-model 4th clutch: Install the waved spring (A) in the 4th 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.





20. 2004-2005-models 5th clutch: Install the waved spring (A) in the 5th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (4) and discs (D) (4), then install the clutch end-plate (E) with the flat side toward the disc.





21. 2006-model 5th clutch: 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.





22. Install the snap ring with a screwdriver to secure the clutch and-plate.
23. Check that the clutch piston moves by applying air pressure into fluid passage.