GSIC - Global Service Information Center

# DIRECT CLUTCH > DISASSEMBLY

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1. INSPECT PACK CLEARANCE OF DIRECT CLUTCH

1. Place the direct clutch assembly onto the O/D support assembly.

1. Using SST and a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (186 to 206 kPa (1.9 to 2.1 kgf/cm2, 27 to 30 psi)).

   SST
     09350-30020 (09350-06120)

   Pack clearance:
     0.40 to 0.70 mm (0.016 to 0.028 in.)
   If the pack clearance is not as specified, parts may have been assembled incorrectly. Check and reassemble again.

   HINT:
   1. If the pack clearance is still not as specified, select another flange.
   2. There are 8 different flange thicknesses.

   Flange thickness:
   No. | Thickness | No. | Thickness
   53 | 3.3 mm (0.130 in.) | 57 | 3.7 mm (0.146 in.)
   54 | 3.4 mm (0.134 in.) | 58 | 3.8 mm (0.150 in.)
   55 | 3.5 mm (0.138 in.) | 60 | 4.0 mm (0.157 in.)
   56 | 3.6 mm (0.142 in.) | 62 | 4.2 mm (0.165 in.)

2. REMOVE DIRECT CLUTCH FLANGE

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

1. Remove the flange, 5 plates and 5 discs.

3. INSPECT DIRECT CLUTCH FLANGE

1. Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage.

   NOTICE:
     Before assembling new discs, soak them in ATF for at least 15 minutes.

4. REMOVE DIRECT CLUTCH RETURN SPRING

5. INSPECT DIRECT CLUTCH RETURN SPRING

1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

   Standard free length:
     21.32 mm (0.839 in.)
   If the length is not as specified, replace the spring.

6. REMOVE DIRECT CLUTCH PISTON

1. Place the direct clutch drum onto the overdrive support.

1. Hold the direct clutch piston, and apply compressed air (196 kPa (2.0/kgf cm2, 28.5 psi)) to the overdrive support to remove the direct clutch piston.

   HINT:
     Make sure the direct clutch piston is at a right angle to the drum before applying compressed air.

1. Remove the direct clutch piston.

1. Using a small screwdriver, remove the 2 O-rings from the piston.

7. INSPECT DIRECT CLUTCH PISTON

1. Check that the check ball is free by shaking the piston.

1. Check that the valve does not have leaks by applying low-pressure compressed air.

8. INSPECT DIRECT CLUTCH DRUM

1. Using a dial indicator, measure the inside diameter of the clutch drum bush.

   Maximum inside diameter:
     53.97 mm (2.1248 in.)
   If the inside diameter is greater than the maximum, replace the clutch drum.