Underdrive Clutch

UNDERDRIVE CLUTCH

COMPONENTS:

DISASSEMBLY





1. REMOVE NO. 2 UNDERDRIVE CLUTCH FLANGE HOLE SNAP RING
(a) Using a screwdriver, remove the No. 2 underdrive clutch flange hole snap ring.





2. REMOVE NO. 1 UNDERDRIVE CLUTCH DISC
(a) Remove the flange, 3 discs, and 3 plates from the underdrive clutch drum.





3. REMOVE UNDERDRIVE CLUTCH RETURN SPRING SUBASSEMBLY
(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 seat is lowered to the place 1 to 2 mm (0.039 to 0.078 inch) from the snap ring groove. This prevents the spring seat from being deformed.
^ Do not expand the snap ring excessively.





(c) Remove the clutch balancer from the underdrive clutch drum.





(d) Remove the return spring from the underdrive clutch drum.





4. REMOVE UNDERDRIVE CLUTCH PISTON SET
(a) Remove the underdrive clutch from the transaxle case.

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

(b) Holding the underdrive clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm 2, 57 psi) to the transaxle case to remove the underdrive clutch piston.





5. REMOVE UNDERDRIVE CLUTCH DRUM O-RING
(a) Using a screwdriver, remove the O-ring from the underdrive clutch drum.

INSPECTION





1. INSPECT UNDERDRIVE PACK CLEARANCE
(a) Install the underdrive 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 underdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm, 57 psi).
Pack clearance: 1.51 to 1.71 mm (0.0594 to 0.0673 inch)
If the pack clearance is not within the specified range, inspect the discs, plates, and flange.





2. INSPECT NO. 1 UNDERDRIVE CLUTCH DISC
(a) Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them.

HINT:
^ If the lining of a disc comes off or discolors, or even if a part of the groove is damaged, replace all discs.
^ Before assembling new discs, soak them in ATF for at least 15 minutes.





3. INSPECT UNDERDRIVE CLUTCH DRUM SUBASSEMBLY
(a) Using a dial indicator, measure the inside diameter of the underdrive clutch drum bushing.
Standard inside diameter: 32.56 to 32.58 mm (1.2818 to 1.2826 inch)
Maximum inside diameter: 32.63 mm (1.2846 inch)
If the inside diameter is greater than the maximum, replace the underdrive clutch drum.





4. INSPECT UNDERDRIVE CLUTCH RETURN SPRING SUBASSEMBLY
(a) Using vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 17.14 mm (0.6748 inch)
If the free length is shorter than the standard free length, replace the underdrive clutch return spring subassembly.

REASSEMBLY





1. INSTALL UNDERDRIVE CLUTCH DRUM O-RING
(a) Coat a new O-ring with ATF, and install it to the underdrive clutch drum.

NOTICE: Install the O-ring carefully not to have a twist or a pinching.





2. INSTALL UNDERDRIVE CLUTCH PISTON SET
(a) Coat the underdrive clutch piston with ATF, and install it to the underdrive clutch piston drum.

NOTICE:
^ Be careful not to damage the O-ring.
^ Be careful not to damage the lip seal of the piston.





3. INSTALL UNDERDRIVE CLUTCH RETURN SPRING SUBASSEMBLY
(a) Install the return spring to the underdrive clutch drum.

NOTICE: After installing the spring subassembly, check all of the springs are fitted in the piston correctly.

(b) Coat the clutch balancer with ATF.





(c) Install the clutch balancer to the underdrive clutch drum.

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





(d) Place SST on the clutch balancer and compress the piston return spring with a press.
SST 09350-32014 (09351-32070)
(e) Using a snap ring expander, install the snap ring to the underdrive clutch drum.

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





(f) Position the end gap of the snap ring in the underdrive clutch drum as shown in the illustration.

NOTICE: The end gap of the snap ring should not be aligned with any of the stoppers.





4. INSTALL NO. 1 UNDERDRIVE CLUTCH DISC
(a) Coat the 3 discs with ATF.
(b) Install the 3 plates, 3 discs, and flange to the underdrive clutch drum.

NOTICE: Be careful about the order of discs, plates, and flange.





5. INSTALL NO. 2 UNDERDRIVE CLUTCH FLANGE HOLE SNAP RING
(a) Using a screwdriver, install the No. 2 underdrive clutch flange hole snap ring.
(b) Check that the end gap of the snap ring is not aligned with one of the cutouts.

NOTICE: The snap ring should be securely engaged in the groove of the drum.