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Assembly Procedure

  1. Apply ATF to the inner and outer faces of the seals and install them to the reverse piston.

    Seal Ring Inner Diameter Inner Seal: 

    1. 160.5 mm {6.319 in} 
    2. Outer Seal: 188.0 mm {7.402 in} 

  2. Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the reverse and forward drum.
    Fig 1: Installing Outer Seal Lip
    G03186171
  3. Install the reverse piston by pushing evenly around the circumference, being careful not to damage the seal rings.
  4. Install the piston return spring with the tabs facing upward.
  5. Install the return spring stopper with the step facing upward.
    Fig 2: Installing Return Spring Stopper
    G03186172
  6. Install the snap ring half-way down the reverse and forward drum as shown.
    Fig 3: Installing Snap Ring
    G03186173
  7. Install the SSTs  on the reverse and forward drum.
    CAUTION:
    • Depress the spring retainer only enough to install the snap ring. Overpressing will damage the retainer assembly edges.
  8. Compress the piston return spring component.
    Fig 4: Compressing Piston Return Spring
    G03186174
  9. Install the snap ring.
  10. Remove the SSTs  .
  11. Install the drive and driven plates in the following order.

    Driven-Drive-Driven-Drive 

    Fig 5: Drive & Driven Plate Installation Order
    G03186175
  12. Install the retaining plate.
  13. Install the snap ring.
  14. Measure the reverse clutch clearance between the retaining plate and the drive plate.
    • If the clearance is not within the specification, adjust it by selecting a proper snap ring from below.

    Reverse Clutch Clearance 

    1. 1.5-1.8 mm {0.059-0.070 in} 

    Snap Ring Sizes 

    SNAP RING SIZES (mm {in})

    2.0 {0.079} 2.2 {0.087} 2.4 {0.094}
    2.6 {0.1 02} 2.8 {0.110} -
  15. Apply ATF to the inner and outer faces of the seals, and install them onto the coasting clutch drum.

    Seal Ring Inner Diameter 

    1. Inner Seal: 71.02 mm {2.796 in} 
    2. Outer Seal: 137.0 mm {5.394 in} 

  16. Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the reverse and forward drum.
    Fig 6: Installing Reverse & Forward Drum Outer Seal Lip
    G03186176
  17. Install the reverse piston by pushing evenly around the circumference, being careful not to damage the seal rings.
  18. Apply ATF to the inner and outer faces of the seals and install them onto the coasting clutch piston.

    Seal Ring Inner Diameter 

    1. Outer Seal: 122.02 mm {4.804 in} 

  19. Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the coasting clutch drum.
    Fig 7: Installing Coasting Clutch Piston Outer Seal Lip
    G03186177
  20. Install the coasting clutch piston by pushing evenly around the circumference, being careful not to damage the outer seal.
  21. Install the spring and retainer component.
  22. Install the SSTs  in the coasting clutch.
    CAUTION:
    • Depress the spring retainer only enough to install the snap ring. Overpressing will damage the retainer assembly edges.
  23. Compress the spring and retainer.
  24. Install the snap ring.
  25. Remove the SST  .
    Fig 8: Removing Spring Compressor
    G03186178
  26. Install the dished plate with the dished side facing upward.
  27. Install the drive and driven plates in the following order.

    Driven-Drive-Driven-Driven-Drive 

    Fig 9: Drive & Driven Plate Installation Order
    G03186179
  28. Install the retaining plate.
  29. Install the coasting clutch snap ring in the direction shown in the figure.
    Fig 10: Installing Coasting Clutch Snap Ring
    G03186180
  30. Measure the clearance between the retaining plate and the snap ring. Make several measurements and calculate the average value.
    • If the clearance is not within the specification, adjust it by selecting a proper snap ring from below.

    Coasting Clutch Clearance 

    1. 1.0-1.2 mm {0.039-0.047 in} 

    Snap Ring Sizes 

    SNAP RING SIZES (mm {in})

    1.50 {0.059} 1.65 {0.065} 1.80 {0.071}
    1.95 {0.077} 2.10 {0.083} 2.25 {0.089}
  31. Install the dished plate with the dished side facing downward.
  32. Install the drive and driven plates in the following order.

    Driven-Drive-Driven- Drive-Driven-Drive 

    Fig 11: Drive & Driven Plate Installation Order
    G03186181
  33. Install the retaining plate.
  34. Install the forward clutch snap ring in the direction shown in the figure.
    Fig 12: Installing Forward Clutch Snap Ring
    G03186182
  35. Measure the clearance between the retaining plate and the snap ring. Make several measurements and calculate the average value.
    • If the clearance is not within the specification, adjust it by selecting a proper snap ring from below.

    Forward Clutch Clearance 

    1. 0.97-1.20 mm {0.038-0.047 in} 

    Snap Ring Sizes 

    FORWARD CLUTCH CLEARANCE SNAP RING SIZES (mm {in})

    2.00 {0.079} 2. 15 {0.085} 2.30 {0.091}
    2.45 {0.096} 2.60 {0.1 02} 2.75 {0.1 08}
  36. Set the clutch component onto the oil pump.
    WARNING:
    • Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air.
    CAUTION:
    • Applying compressed air to the assembled clutch pack for longer than 3 seconds at a time will damage the seal. Do not apply compressed air for more than the aforementioned time when testing the system.
  37. Inspect the clutch operation by applying compressed air through the fluid passages shown.

    Air Pressure 

    1. 390 kPa {4.0 kgf/cm 2  , 57 psi} max. 

    Fig 13: Inspecting Clutch Operation
    G03186183
  38. Apply petroleum jelly to the thrust bearings, and secure them onto reverse and forward drum.

    Thrust Bearing Outer Diameter 

    1. Oil Pump Side: 86.1 mm {3.39 in} 
    2. Small Sun Gear And One-Way Clutch 1 Side: 56.1 mm {2.21 in} 

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