Direct Clutch

Direct Clutch:

COMPONENTS

DISASSEMBLY OF DIRECT CLUTCH



1. REMOVE SNAP RING FROM CLUTCH DRUM
2. REMOVE FLANGE, DISCS AND PLATES




3. COMPRESS PISTON RETURN SPRING AND REMOVE SNAP RING
Place SST on the spring retainer and compress the springs with a shop press. Using a screwdriver, remove the snap ring.

SST 09350 - 32014 (09351 - 32070)

4. REMOVE PISTON RETURN SPRING




5. ASSEMBLE DIRECT CLUTCH ON OIL PUMP AND BLOW OUT PISTON
a. Slide the direct clutch onto the oil pump.
b. Apply compressed air to the oil pump to remove the piston. (If the piston does not come out completely, use needle-nose pliers to remove it.)
c. Remove the direct clutch from the oil pump.

6. REMOVE CLUTCH PISTON O-RING

ASSEMBLY OF DIRECT CLUTCH




1. INSTALL CLUTCH PISTON IN DIRECT CLUTCH DRUM
a. Install new O-rings on the piston; Coat the O-rings with ATF.
b. Press the piston into the drum with the cup side up, being careful not to damage the O-ring.




2. SET PISTON RETURN SPRING AND SNAP RING IN PLACE
3. COMPRESS RETURN SPRING AND INSTALL SNAP RING IN GROOVE
a. Place SST on the spring retainer, and compress the spring with a shop press.

SST 09350 - 32014 (09351 - 32070)

b. Install the snap ring with a screwdriver. Be sure the end gap of snap ring is not aligned with the spring retainer claw.




4. INSTALL PLATES, DISCS AND FLANGE
Install in order: Plate-disc-plate-disc-plate-disc Install the flange with the flat end facing downward.




5. INSTALL OUTER SNAP RING
Check that the end gap of snap ring is not aligned with one of the cutouts.

6. CHECK PISTON STROKE OF DIRECT CLUTCH
If replacing the disc, plate or flange, check the piston stroke.




a. Install the direct clutch on the oil pump.




b. Using a dial indicator (long type pick or SST), measure the direct clutch piston stroke applying and releasing the compressed air (4 - 8 kg/sq.cm, 57 - 114 psi or 392 - 785 kPa) as shown.

SST 09350 - 32014 (09351 - 32190)

Piston stroke: 1.11 - 1.44 mm(0.0437 - 0.0567 in.)

If the piston stroke is less than the limit, parts may be misassembled and reinstall them.

If the piston stroke nonstandard, select another flange.

NOTE: There are two different thickness for the flange.

Flange thickness: 2.60 mm (0.1024 in.)
3.00 mm (0.1181 in.)




7. CHECK OPERATION OF DIRECT CLUTCH
Apply compressed air into the passage with the oil pump body and be sure that the piston moves.

If the piston does not move, disassemble and inspect.

INSPECTION OF DIRECT CLUTCH




1. INSPECT CLUTCH PISTON
a. Check that check ball is free by shaking the piston.
b. Check that the valve does not leak by applying low-pressure compressed air.




2. INSPECT DISC. PLATE AND FLANGE
Check if the sliding surface of the discs, plates and flanges are worn or burnt. If necessary, replace them.

NOTE:
- If the lining of the disc is exfoliated or discolored, or even a part of the printed numbers are defaced, replace all discs.
- Before assembling new discs, soak them in ATF for at least two hours.