Forward Clutch

DISASSEMBLY





1. CHECK PISTON STROKE OF FORWARD CLUTCH
a. Install the forward clutch on the oil pump.

NOTICE: Be careful not to damage the oil seal ring of the oil pump.

b. Using a dial indicator, measure the forward clutch piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Piston stroke: 1.41 - 1.75 mm (0.0555 - 0.0689 inch)
If the clearance is non-standard, inspect the discs, plates and flange.

HINT: As the opening is big, cover it with a shop rug to prevent air leakage.





2. REMOVE FLANGE, PLATE AND DISC
Remove the oil seal ring from the forward clutch drum.
3. REMOVE FLANGE, PLATE AND DISC





a. Using a screwdriver, remove the snap ring from the forward clutch drum.





b. Remove the flange, 4 discs and 4 plates.
4. REMOVE PISTON RETURN SPRING





a. Place SST on the spring retainer and compress the return spring with a press.
SST 09350-32014 (09351-32070)
b. Using a snap ring expander, remove the snap ring.





c. Remove the piston return spring.





5. REMOVE FORWARD CLUTCH PISTON
a. Place the forward clutch drum onto the oil pump.
b. Holding the forward clutch piston by hard, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil pump to remove the forward clutch piston.

HINT: When the piston can not be removed as it is slanted, either blow the air again with the protruding side pushed or remove the piston using needle-nose pliers with vinyl tape on the tip.





6. REMOVE O-RING
Remove the 2 O-rings.

INSPECTION





1. INSPECT DISC, PLATE AND FLANGE
Check if the sliding surface of the disc, plate and flange are worn or burnt.
If necessary, replace them.

HINT:
^ If the lining of the disc is peeled off or discolored, replace all the discs.
^ Before assembling new discs, soak them in ATF for at least 15 minutes.

2. CHECK FORWARD CLUTCH PISTON





a. Shake the piston to check that the check ball is not stuck.





b. Check that the valve does not leak when applying low compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).





3. CHECK FORWARD CLUTCH PISTON RETURN SPRING
Using vernier calipers, measure the free length of the spring with spring seat.
Standard free length: 28.23 mm (1.1114 inch)





4. CHECK MULTIPLE DISC CLUTCH HUB BUSHING
Using a dial indicator, measure the inside diameter of the forward clutch hub bushing.
Standard inside diameter: 23.025 - 23.045 mm (0.90649 - 0.90728 inch)
Maximum inside diameter: 23.09 mm (0.9091 inch)

NOTICE:
^ When the diameter is over the maximum, replace the multiple disc clutch hub with new one.
^ Check the contact surface of the bush in the direct clutch shaft. If any scratch or discolor is identified, replace the direct clutch sub-assembly with new one.

If the inside diameter is greater than the maximum, replace the forward clutch hub.

REASSEMBLY
1. INSTALL FORWARD CLUTCH PISTON





a. Coat 2 new O-rings with ATF, and install them to the forward clutch piston.





b. Install the forward clutch piston to the forward clutch drum.
2. INSTALL PISTON RETURN SPRING





a. Place the return spring onto the piston.





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

NOTICE:
^ Stop the press when the spring sheet Is lowered to the place of 1 - 2 mm (0.039 - 0.078 inch) away from the snap ring groove.
^ This prevents the spring sheet from being deformed.
^ Do not expand the snap ring excessively.





3. INSTALL PLATE, DISC AND FLANGE
Install the 4 plates and 4 discs in order.
Install In order: P=Plate, D=Disc, F=Flange
P - D - P - D - P - D - P - D - F





4. INSTALL SNAP RING
a. Using a screwdriver, install the snap ring.
b. Check that the end gap of the snap ring is not aligned with one of the cutouts.





5. INSTALL OIL SEAL RING
Install the oil seal ring to the forward clutch drum.





6. CHECK PISTON STROKE OF FORWARD CLUTCH
Using a dial indicator, measure the forward clutch piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Piston stroke: 1.41 - 1.75 mm (0.0555 - 0.0689 inch)
If the piston stroke is less than the minimum, parts may have been assembled incorrectly. Check and reassemble them again. If the clearance is non-standard, select another flange.

HINT: There are 5 flanges in different thickness.





Flange thickness: mm (in.)





7. CHECK DISK ROTATE
Check that the disc rotates lightly when rotating the forward clutch assembly after inserting the multiple disc clutch into it.

NOTICE: Do not place the forward clutch assembly in a vise.