Part 2 of 2

Clutch Inspection





1. Inspect the 4th and 5th clutch pistons and clutch piston check valves (A).
2. If the clutch piston check valve is loose or damaged, replace the clutch piston.
3. Check the spring retainer for wear and damage.





4. Check the oil seal (A) on the spring retainer of the 1st,2nd, and 3rd clutches for wear, damage, and peeling.
5. If the oil seal is worn, damaged, or peeling, replace the spring retainer.
6. Inspect the clutch discs, clutch plates, and clutch end plate for wear, damage, and discoloration.
Standard Thickness
Clutch Discs: 1.94 mm (0.076 inch)
Clutch Plates:
1st clutch (waved-plates): 1.6 mm (0.063 inch)
2nd clutch:
Waved-plates: 2.0 mm (0.079 inch)
Flat-plate: 2.0 mm (0.079 inch)
4.0 mm-thick plate: 4.0 mm (0.157 inch)
3rd clutch:
Waved-plates: 1.6 mm (0.063 inch)
Flat-plates: 1.6 mm (0.063 inch)
4th clutch (waved-plates): 2.0 mm (0.079 inch)
5th clutch (waved-plates): 2.0 mm (0.079 inch)
7. If the clutch discs are worn or damaged, replace them as a set. If the clutch discs are replaced, inspect the clutch end-plate-to-top-disc clearance.
8. If any plate is worn, damaged, or discolored, replace the damaged plate with the new plate, and inspect the other waved-plates for a phase difference. If the clutch plate is replaced, inspect the clutch end-plate-to-top-disc clearance.
9. If the clutch end plate is worn, damaged, or discolored, inspect the clutch end-plate-to-top-disc clearance, then replace the clutch end plate.

Clutch Waved-plate Phase Difference Inspection





1. Place the clutch waved-plate (A) on a surface plate, and set a dial indicator (B) on the waved-plate.
2. Find the bottom (D) of a phase difference of the waved-plate, zero the dial indicator and make a reference mark on the bottom of the waved-plate.
3. Rotate the waved-plate about 60-degrees apart from the bottom while holding the waved-plate by its circumference. The dial indicator should be at the top (E) of a phase difference. Do not rotate the waved-plate while holding its surface, always rotate it with holding its circumference.
4. Read the dial indicator. The dial indicator reads the phase difference (C) of the waved-plate between bottom and top.
Standard: 0.05 mm (0.002 inch) minimum
5. Rotate the waved-plate about 60-degrees. The dial indicator should be at the bottom of a phase difference (F and H), and zero the dial indicator.
6. Measure the phase difference at the other two tops (G and I) of the waved-plate by following steps 3 thru 5.
7. If the two values of the three measurements are within the standard, the waved-plate is OK. If the two values of the three measurements are out of the standard, replace the waved-plate.

Clutch Clearance Inspection

Special Tools Required
- Clutch compressor attachment 07ZAE-PRP0100

1. Inspect the clutch piston, discs, plates, and end plate for wear and damage, and inspect clutch waved-plate phase difference, if necessary.





2. Install the clutch piston in the clutch drum. Do not install the O-rings during inspection.





3. Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch plate, alternately install the clutch plate (C) (5) and discs (D) (5), then install the clutch-end-plate (E) with the flat side toward the disc.





4. Install the waved spring (A) in the 2nd clutch drum (B). Install the 4.0 mm-thick plate (C) with the shear droop side (D) toward the inside of the drum, clutch disc (E), and 2.0 mm-thick flat-plate (F), then starting with the disc, alternately install the discs (4) (G) and waved-plates (3) (H), then install the clutch-end-plate (I) with the flat side toward the disc.





5. Install the waved spring (A) in the 3rd clutch drum (B). Starting with the clutch plate, alternately install the clutch plate (C) (5) and discs (D) (5), then install the clutch-end-plate (E) with the flat side toward the disc.





6. Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (4) and discs (D) (4), then install the clutch-end-plate (E) with the flat side toward the disc.





7. Install the waved spring (A) in the 5th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (4) and discs (D) (4), then install the clutch-end-plate (E) with the flat side toward the disc.





8. Install the snap ring with a screwdriver.





9. Set a dial indicator (A) on the clutch end plate (B).
10. Zero the dial indicator with the clutch end plate lifted up to the snap ring (C).





11. Release the clutch end plate to lower the clutch end plate, then put the special tool on the end plate (A).
12. For 2nd, 4th and 5th clutches: Press the special tool down with 150 - 160 N (15 - 16 kgf, 33 - 35 ft. lbs.) using a force gauge, and read the dial indicator (B).
13. For 1st and 3rd clutches: Press the special tool down with 39 N (4.0 kgf, 9 ft. lbs.) using a force gauge, and read the dial indicator (B).
14. The dial indicator reads the clearance (C) between the clutch end plate and top disc (D). Take measurements in at least three places, and use average as the actual clearance.
Service Limit:
1st Clutch: 0.82 - 1.02 mm (0.032 - 0.040 inch)
2nd Clutch: 0.88 - 1.08 mm (0.035 - 0.043 inch)
3rd Clutch: 0.82 - 1.02 mm (0.032 - 0.040 inch)
4th Clutch: 0.88 - 1.08 mm (0.035 - 0.043 inch)
5th Clutch: 0.88 - 1.08 mm (0.035 - 0.043 inch)














15. If the clearance is out of the service limit, select a new clutch end plate from the table shown.
16. Install the new clutch end plate, then recheck the clearance.
17. If the thickest crutch end plate is installed, but the clearance is still over the service limit, replace the clutch discs and plates.

Clutch Reassembly

Special Tools Required
- Clutch spring compressor attachment 07LAE-PX40100
- Clutch spring compressor attachment 07HAE-PL50101
- Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A

1. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.





2. Install the new O-rings (A) on the 4th and 5th clutch piston (B).





3. Install the new O-ring (A) in the 1st, 2nd, and 3rd clutch pistons (B), and install the new O-ring (C) on the clutch drums (D).





4. Install the clutch piston (A) in the clutch drum (B). Apply pressure and rotate to ensure proper seating. Lubricate the piston O-ring with ATF before installing. Do not pinch the O-ring by installing the piston with too much force.





5. Install the return spring (A) and spring retainer (B), and position the snap ring (C) on the retainer.





6. Install the special tools.





7. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 4th and 5th clutches.





8. Set the special tool (A) on the spring retainer (B) of the 1st, 2nd, and 3rd clutches in such a way that the special tool compresses the clutch return spring (C).





9. If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.





10. Compress the return spring.





11. Install the snap ring with snap ring pliers.
12. Remove the special tools.





13. Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch plate, alternately install the clutch plate (C) (5) and discs (D) (5), then install the clutch-end-plate (E) with the flat side toward the disc.





14. Install the waved spring (A) in the 2nd clutch drum (B). Install the 4.0 mm-thick plate (C) with the shear droop side (D) toward the inside of the drum, clutch disc (E), and 2.0 mm-thick flat-plate (F), then starting with the disc, alternately install the discs (4) (G) and waved-plates (3) (H), then install the clutch-end-plate (I) with the flat side toward the disc.





15. Install the waved spring (A) in the 3rd clutch drum (B). Starting with the clutch plate, alternately install the clutch plate (C) (5) and discs (D) (5), then install the clutch-end-plate (E) with the flat side toward the disc.





16. Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (4) and discs (D) (4), then install the clutch-end-plate (E) with the flat side toward the disc.





17. Install the waved spring (A) in the 5th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (4) and discs (4) (D), then install the clutch-end-plate (E) with the flat side toward the disc.





18. Install the snap ring with a screwdriver.
19. Check that the clutch piston moves by applying air pressure into fluid passage.