Part 2
Shafts and Clutches Continued4th and 5th Clutch Disassembly
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 with a screwdriver.
2. Remove the clutch end plate (A), clutch discs (B) (4), clutch wave-plates (C) (4), and wave spring (D) from the 4th clutch drum (E).
3. Remove the clutch end plate (A), clutch discs (B) (4), clutch wave-plates (C) (4), and wave spring (D) from the 5th clutch drum (E).
4. Install the clutch spring compressor attachments and the clutch spring compressor bolt assembly.
5. Be sure the clutch spring compressor attachment (A) is adjusted to have full contact with the return spring retainer (B).
6. 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.
7. Compress the return spring until the snap ring can be removed.
8. Remove the snap ring with the snap ring pliers.
9. Remove the clutch spring compressor attachments and the clutch spring compressor bolt assembly.
10. Remove the snap ring (A), spring retainer (B), and return spring (C).
11. 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.
12. Remove the clutch piston (A), and remove the outer O-ring (B) and inner O-ring (C) from the piston.
Clutch Inspection
1. Inspect the 4th and 5th 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. Inspect the clutch discs, clutch-plates, and clutch end plate for wear, damage, and discoloration.
Standard Thickness:
Clutch Discs: 1.94 mm (0.076 in.)
Clutch Plates:
1st clutch (wave-plates): 1.6 mm (0.063 in.)
2nd clutch: Wave-plates: 2.0 mm (0.079 in.)
Flat-plate: 2.0 mm (0.079 in.)
3rd clutch: Wave-plates: 1.6 mm (0.063 in.)
Flat-plates: 1.6 mm (0.063 in.)
4th clutch (wave-plates): 2.0 mm (0.079 in.)
5th clutch (wave-plates): 2.0 mm (0.079 in.)
5. 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.
6. If any plate is worn, damaged, or discolored, replace the damaged plate with the new plate, and inspect the other wave-plates for a phase difference. If the clutch plate is replaced, inspect the clutch end-plate-to-top disc clearance.
7. 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 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 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 with holding its circumference.
4. Read the dial indicator. The dial indicator reads the phase difference (E) of the wave-plate between bottom and top.
Standard Phase Difference:
1st clutch: 0.15-0.25 mm (0.006-0.010 in.)
2nd clutch: 0.1-0.2 mm (0.004-0.008 in.)
3rd clutch: 0.1-0.2 mm (0.004-0.008 in.)
4th clutch: 0.1-0.2 mm (0.004-0.008 in.)
5th clutch: 0.1-0.2 mm (0.004-0.008 in.)
5. Rotate the 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
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 end plate for wear and damage, and inspect the clutch wave-plate phase difference, if necessary.
2. Install the wave spring (A) in the 1st clutch drum (B). Install the clutch flat-plate (C) (1), then starting with the clutch disc, alternately install the discs (D) (5) and wave-plates (E) (4). Install the clutch end-plate (F) with the flat side down on the top disc.
3. Install the wave spring (A) in the 2nd clutch drum (B). Install the clutch flat-plate (C) (1), then starting with the clutch disc, alternately install the discs (D) (6) and wave-plates (E) (5). Install the clutch endplate (F) with the flat side down on the top disc.
4. Install the wave spring (A) in the 3rd clutch drum (B). Install the clutch flat-plate (C) (1), then starting with the clutch disc, alternately install the discs (D) (6) and wave-plates (E) (5). Install the clutch endplate (F) with the flat side down on the top disc.
5. Install the clutch pistons in the 4th and 5th clutch drums. Do not install the O-rings during inspection.
6. Install the wave spring (A) in the 4th clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (4) and discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
7. Install the wave spring (A) in the 5th clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (4) and discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
8. Install the snap ring with 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 special tool on the end-plate (A).
12. 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.
Clutch End-Plate-to-Top Disc Clearance
Service Limit:
1st Clutch: 1.38-1.58 mm (0.054-0.062 in.)
2nd Clutch: 1.18-1.38 mm (0.046-0.054 in.)
3rd Clutch: 1.23-1.43 mm (0.048-0.056 in.)
4th Clutch: 0.93-1.13 mm (0.037-0.044 in.)
5th Clutch: 0.93-1.13 mm (0.037-0.044 in.)
13. If the clearance is out of the service limit, select a new clutch end-plate from the following tables.
14. 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.
1st, 2nd, and 3rd Clutch Reassembly
1. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.
2. Install the wave spring (A) in the 1st clutch drum (B). Install the clutch flat-plate (C) (1), then starting with the clutch disc, alternately install the discs (D) (5) and wave-plates (E) (4). Install the clutch end-plate (F) with the flat side down on the top disc.
3. Install the wave spring (A) in the 2nd clutch drum (B). Install the clutch flat-plate (C) (1), then starting with the clutch disc, alternately install the discs (D) (6) and wave-plates (E) (5). Install the clutch endplate (F) with the flat side down on the top disc.
4. Install the wave spring (A) in the 3rd clutch drum (B). Install the clutch flat-plate (C) (1), then starting with the clutch disc, alternately install the discs (D) (6) and wave-plates (E) (5). Install the clutch endplate (F) with the flat side down on the top disc.
5. Install the snap ring with a screwdriver to secure the clutch end-plate.
6. Check that the clutch piston moves by applying air pressure into fluid passage.
4th and 5th Clutch Reassembly
Special Tools Required
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A
^ Clutch spring compressor attachment 07LAE-PX40100 or 07HAE-PL50101
1. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.
2. Install the new O-rings (A) on the clutch piston (B). Do not twist the O-rings.
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. Install the return spring (A) and spring retainer (B), and position the snap ring (C) on the spring retainer.
5. Install the clutch spring compressor attachments 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. 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 with the snap ring pliers.
10. Remove the clutch spring compressor attachments and the clutch spring compressor bolt assembly.
11. Install the wave spring (A) in the 4th clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-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 wave spring (A) in the 5th clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (4) and discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
13. Install the snap ring with a screwdriver to secure the clutch end-plate.
14. Check that the clutch piston moves by applying air pressure into fluid passage.