Underdrive Clutch

DISASSEMBLY





1. CHECK PACK CLEARANCE OF U/D CLUTCH
a. Install the U/D clutch to the transaxle case.

NOTICE: Be careful not to damage the oil seal rings.

b. Install a dial indicator, as shown in the illustration.
c. Measure the U/D clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance: 1.51 - 1.90 mm (0.0594 - 0.0748 inch)
If the pack clearance is non-standard, inspect the discs, plates and flange.
2. REMOVE FLANGE, DISC AND PLATE





a. Using a screwdriver, remove the snap ring.





b. Remove the flange, 3 discs and 3 plates from the U/D clutch drum.
3. REMOVE PISTON RETURN SPRING





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

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.





c. Remove the clutch balancer and piston return spring from the U/D clutch drum.





4. REMOVE U/D CLUTCH PISTON
a. Install the U/D clutch to the transaxle case.

NOTICE: Be careful not to damage the oil seal rings.

b. Holding the U/D clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove the U/D clutch piston.





5. REMOVE O-RING

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, or if a part of the printed mark is defaced, replace all the discs.
^ Before assembling new discs, soak them in ATF for at least 15 minutes.





2. CHECK U/D CLUTCH DRUM BUSHING
Using a dial indicator, measure the inside diameter of the U/D clutch drum bushing.
Standard drum bushing: 32.56 - 32.58 mm (1.2818 - 1.2826 inch)
Maximum drum bushing: 32.63 mm (1.2846 inch)
If the inside diameter is greater than the maximum, replace the U/D clutch drum.





3. CHECK U/D CLUTCH PISTON RETURN SPRING
Using vernier calipers, measure the free length of the spring with spring seat.
Standard free length: 17.14 mm (0.6748 inch)

REASSEMBLY





1. INSTALL O-RING
Coat a new O-ring with ATF, and install it to the U/D clutch drum.





2. INSTALL U/D CLUTCH PISTON
Coat the U/D clutch piston with ATF, and install it to the U/D clutch piston drum.

NOTICE: Be careful not to damage the O-ring.

3. INSTALL PISTON RETURN SPRING





a. Install the piston return spring and clutch balancer to the U/D clutch drum.

NOTICE: Be careful not to damage the lip seal of the clutch balancer.





b. Place SST on the clutch balancer and compress the piston return spring with a press.
SST 09350-32014 (09351-32070)
c. Using a snap ring expander, install the snap ring to the U/D clutch drum.

NOTICE:
^ Be sure the end gap of the snap ring is not aligned with the clutch balancer's claw.
^ 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.

4. INSTALL PLATE, DISC AND FLANGE





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





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





5. CHECK PACK CLEARANCE OF U/D CLUTCH
a. Install the U/D clutch to the transaxle case.

NOTICE: Be careful not to damage the oil seal rings.

b. Set a dial indicator, as shown in the illustration.
c. Measure the U/D clutch piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance: 1.51 - 1.90 mm (0.0594 - 0.0748 inch)
If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble them again.
If the pack clearance is non-standard, select another flange.

HINT: There are 3 flanges in different thickness.





Flange Thickness: mm (in.)