Direct Clutch

NOTE: For removal and installation procedures refer to "Automatic Transmission/Transaxle, Service and Repair." Service and Repair

DIRECT CLUTCH DISASSEMBLY








1. Check piston stroke of direct clutch.
a. Install the direct clutch on the oil pump.





b. Set a dial indicator and measuring terminal Special Service Tool (SST) 09350 - 32014 (09351 - 32190), or equivalent, together, measure the direct clutch piston stroke while applying and releasing compressed air (392 - 785 kPa, 4 - 8 kgf-cm2, 57 - 1 14 psi).
Piston stroke: 1.63 - 1.97 mm (0.0642 - 0.0776 in.)
If the piston stroke is greater than the maximum inspect the each component.





2. Remove snap ring from clutch drum.
3. Remove flange, discs and plates.





4. Remove piston return spring.
a. Place SST 09350 - 32014 (09351 - 32070) on the spring retainer and compress the springs with a shop press.
b. Remove the snap ring with the snap ring pliers.





c. Remove the piston return spring.





5. Remove clutch piston.
a. Install the direct clutch 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.





d. Remove the 2 O-rings from the piston.


DIRECT CLUTCH INSPECTION






1. Inspect clutch piston.
a. Check that the 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.

HINT: If the lining of the disc is peeling off or discolored, or even if a part of the printed number is defaced, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes.






3. Check direct clutch bushing.
Using a dial indicator, measure the inside diameter of the direct clutch bushing.
Maximum inside diameter: 47.07 mm (1.8531 in.)
If the inside diameter is greater than the maximum, replace the direct clutch.


DIRECT CLUTCH ASSEMBLY






1. Install clutch piston in direct clutch drum.
a. Install new O-rings to the piston. Coat the O-rings with ATF.
b. Being careful not to damage the O-rings, press the piston into the drum with the cup side up.





2. Install piston return spring.
a. Place the return spring and snap ring onto the piston.
b. Place SST 09350 - 32014 (09351 - 32070) on the return spring, and compress the return spring with a shop press.
c. Install the snap ring with the snap ring pliers. Be sure the end gap of snap ring is not aligned with the spring retainer claw.





3. Install plates, discs and flange.
a. Install plates and discs in order.
P = Plate D = Disc F = Flange C = Cushion Plate
- C-P-D-P-P-D-F

b. Install the flange with the flat end facing downward.





4. Install snap ring.
Check that the end gap of the snap ring is not aligned with one of the cutouts.





5. Recheck piston stroke of direct clutch.
a. Install the direct clutch on the oil pump.
b. Set a dial indicator and measuring terminal SST 09350 - 32014 (09351 - 32190) together, measure the direct clutch piston stroke while applying and releasing compressed air (392 - 785 kPa, 4 - 8 kgf-cm2, 57 - 1 14 psi).





Piston stroke: 1.63 - 1.97 mm (0.0642 - 0.0776 in.)
If the piston stroke is non-standard, select another flange.

HINT: There are 3 different thicknesses for the flange.

Flange thicknesses:
- 2.6 mm (0.102 in.)
- 2.8 mm (0.110 in.)
- 3.0 mm (0.118 in.)