DISASSEMBLY AND REASSEMBLY







Disassembly steps


1.
Seal ring


2.
Snap ring


3.
Input shaft

>>H<<
4.
Snap ring

>>G<<
5.
Reaction plate

>>G<<
6.
Clutch disc

>>G<<
7.
Clutch plate

>>F<<
8.
Snap ring

>>E<<
9.
Reaction plate

>>E<<
10.
Clutch disc

>>E<<
11.
Clutch plate
<<A>>
>>D<<
12.
Snap ring


13.
Spring retainer

>>A<<
14.
D-ring

>>C<<
15.
Return spring


16.
Overdrive clutch piston

>>A<<
17.
D-ring

>>B<<
18.
Reverse clutch piston

>>A<<
19.
D-ring

>>A<<
20.
D-ring

>>A<<
21.
D-ring


22.
Reverse clutch retainer

DISASSEMBLY SERVICE POINT



<<A>> SNAP RING REMOVAL



1.Set the special tools as shown in the illustration.

  • Spring compressor (MD999590)
  • Spring compressor retainer (MD998924)
2.Compress the return spring, and remove the snap ring.

REASSEMBLY SERVICE POINTS



>>A<< D-RING INSTALLATION


1.Apply ATF to the D-ring.
2.Install the D-rings in the reverse clutch retainer, piston, overdrive clutch piston and spring retainer grooves. Make sure that they are not twisted or damaged when installing.

>>B<< REVERSE CLUTCH PISTON INSTALLATION



Align the holes ("A" and "B") in the reverse clutch piston and reverse clutch retainer and then assemble.

>>C<< RETURN SPRING INSTALLATION



Align the two return spring holes with the two projections on the overdrive clutch piston, and then assemble the return springs.

>>D<< SNAP RING INSTALLATION



1.Set the special tools as shown in the illustration.

  • Spring compressor (MD999590)
  • Spring compressor retainer (MD998924)
2.Tighten the special tool nut, and press the spring retainer against the reverse clutch retainer.
3.Install the thickest snap ring that can be fitted in the snap ring groove of the reverse clutch retainer.
4.Confirm that clearance between the snap ring and spring retainer is the standard value.
Standard value: 0 - 0.09 mm

>>E<< CLUTCH PLATE/CLUTCH DISC/REACTION PLATE INSTALLATION


1.Alternately assemble the clutch discs and clutch plates in the reverse clutch piston.

2.Install the reaction plate so that it is oriented as shown in the illustration.

>>F<< SNAP RING INSTALLATION


1.Install the snap ring in the reverse clutch piston groove.


2.Set the special tools as shown in the illustration, and compress the clutch element.

  • Spring compressor (MB991629)
  • Spring compressor retainer (MD998924)
3.Confirm that the clearance between the snap ring and reaction plate (overdrive clutch end play) is the standard value. If the clearance is not at the standard value, select a suitable snap ring and adjust so that the clearance is within the standard value.
Standard value: 2.0 - 2.2 mm

>>G<< CLUTCH PLATE/CLUTCH DISC/REACTION PLATE INSTALLATION




1.Alternately assemble the clutch plates and clutch discs in the reverse clutch retainer.
When assembling the clutch plates, align the section having no teeth (A in the illustration) with the reverse clutch retainer hole (B in the illustration).
2.Install the reaction plate so that it is oriented as shown in the illustration.
Assemble in the same manner as the clutch plate so that the section with no teeth ("A" in the illustration) matches the retainer hole ("B" in the illustration).

>>H<< SNAP RING INSTALLATION


1.Install the snap ring in the reverse clutch retainer groove.

2.Set the special tools as shown in the illustration, and compress the clutch element.

  • Spring compressor (MB991789)
  • Spring compressor retainer (MD998924)
3.Check that the clearance between the snap ring and reaction plate (reverse clutch end play) is the standard value.
If the clearance is not at the standard value, select a suitable snap ring and adjust so that the clearance is within the standard value.
Standard value: 1.5 - 1.7 mm