Direct Clutch Disassembly/Assembly

DIRECT CLUTCH





DISASSEMBLY





1. Install direct clutch assembly to center support and with 4-8 kgs.cm2 air pressure applied to second fluid hole from the left, measure stroke of direct clutch piston as shown in figure.

Standard direct clutch piston stroke: 0.19-1.75 mm (0.008-0.068 inch)

If it is not within standard range, use 3.6 mm, 3.8 mm or 4.0 mm (0.141 in, 0.149 in or 0.157 inch) clutch backing plate to adjust it to standard stroke.





2. Remove direct clutch assembly from center support and then remove retaining ring.





3. Remove clutch backing plate and then remove clutch disc and clutch plate.





4. Using special tool and hydraulic press, compress direct clutch piston return spring and remove retaining return spring ring.

Special Tool (A): 09926-98310

CAUTION: Be careful when applying pressure, for overpressure will cause plate section of piston return spring to deform.





5. Remove direct clutch piston return spring.
6. Install direct clutch cylinder to center support.
Remove direct clutch piston by blowing air into the second hole from the left as shown in image. Also, remove direct clutch inner piston by blowing air into hole at the extreme right. And then remove O-rings from pistons.

INSPECTION

DIRECT CLUTCH PISTON RETURN SPRING





- Measure free length.

Standard free length of direct clutch piston return spring: 15.13 mm (0.595 inch)

DIRECT CLUTCH PISTON





- Shake piston to check that ball is not stuck.
- Apply air pressure and check that there is no leakage.

ASSEMBLY





Assemble each component by reversing disassembly procedure and noting following points.
- Always use new O-ring and apply A/T fluid before installation.
- Do not align opening in retaining ring with lug of direct clutch piston return spring at retainer.

Special Tool (A): 09926-98310





- Use care so that direct clutch piston return spring will not fall or tilt.

CAUTION: Be careful when applying pressure, for overpressure will cause plate section of piston return spring to deform.

- Do not match opening in retaining back plate ring with cutout in direct clutch cylinder





- Install clutch backing plate with its grooved side facing the front.