GSIC - Global Service Information Center

# FORWARD CLUTCH > REASSEMBLY

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1. INSTALL INPUT SHAFT OIL SEAL RING

1. Coat the 3 oil seal rings with ATF.

1. Squeeze the ends of the 3 oil seal rings together, and then install them to the forward clutch drum groove.

   NOTICE:
     Do not expand the ring excessively.

   HINT:
     After installing the oil seal rings, check that they rotate smoothly.

2. INSTALL FORWARD CLUTCH PISTON O-RING

1. Coat a new O-ring with ATF, and install it on the forward clutch drum.

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

3. INSTALL FORWARD CLUTCH PISTON

1. Be careful not to damage the O-ring, and press the clutch piston into the forward clutch drum with both hands.

4. INSTALL FORWARD CLUTCH RETURN SPRING

1. Install the piston return spring.

1. Place SST on the spring retainer, and compress the return spring with a press.

   SST
     09350-30020 (09350-07040, 09350-07070)

   NOTICE:
     Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

5. INSTALL FORWARD CLUTCH DISC

1. Install the cushion plate.

1. Install the 6 plates, 6 discs and flange.

   Install in order:
     P - D - P - D - P - D - P - D - P - D - P - D - F

   HINT:
     F = Flange
     P = Plate
     D = Disc

   HINT:
     Only the plate on the bottom is 1.4 mm (0.055 in.) thick. The other plates are 1.8 mm (0.071 in.) thick.

1. Using a screwdriver, install the snap ring.

   NOTICE:
     Be sure the end gap of the snap ring is not aligned with the cutout portion of the forward clutch drum.

6. INSPECT PISTON STROKE OF FORWARD CLUTCH

1. Using SST and a dial indicator, measure the direct clutch piston stroke while applying and releasing compressed air (392 kPa (4.0 kgf/cm2, 57 psi)).

   SST
     09350-30020 (09350-06120)

   Piston thickness:
     0.60 to 1.00 mm (0.024 to 0.039 in.)
   If the piston stroke is not as specified, parts may have been assembled incorrectly. Check and reassemble again.

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

      Piston stroke:

        No. | Thickness | No. | Thickness
        90 | 3.0 mm (0.118 in.) | 94 | 3.8 mm (0.150 in.)
        91 | 3.2 mm (0.126 in.) | 95 | 4.0 mm (0.157 in.)
        92 | 3.4 mm (0.134 in.) | 96 | 4.2 mm (0.165 in.)
        93 | 3.6 mm (0.142 in.) | 97 | 4.4 mm (0.173 in.)