DISASSEMBLY AND REASSEMBLY

1. Thrust bearing race 2. Thrust needle roller bearing 3. Seal ring 4. Input shaft sub-assembly 5. O-ring 6. O-ring 7. Forward clutch piston 8. Forward clutch return spring sub-assembly 9. O-ring 10. Forward clutch balancer 11. Shaft snap ring 12. Forward clutch flange 13. Forward clutch disc 14. Forward clutch plate 15. Forward clutch flange 16. Hole snap ring 17. Thrust needle roller bearing 18. Thrust bearing race 19. Forward clutch hub 20. Thrust bearing race No. 2

21. Shaft snap ring 22. Reverse clutch balancer 23. Reverse clutch return spring sub-assembly 24. O-ring 25. Reverse clutch piston sub-assembly 26. O-ring 27. Reverse clutch drum sub-assembly 28. O-ring 29. Direct clutch piston 30. Direct clutch return spring sub-assembly 31. Direct clutch balancer 32. Shaft snap ring 33. Direct clutch plate 34. Direct clutch disc 35. Reverse clutch flange 36. Hole snap ring 37. Hole snap ring 38. Thrust bearing race No. 2 39. Thrust needle roller bearing 40. Direct clutch hub sub-assembly 41. Reverse clutch flange 42. Thrust needle roller bearing 43. Reverse clutch hub sub-assembly 44. Reverse clutch disc 45. Reverse clutch plate 46. Reverse clutch flange 47. Clutch cushion plate 48. Reverse clutch reaction sleeve 49. Hole snap ring

1.Using a screwdriver, remove the hole snap ring from the reverse clutch piston sub-assembly. 2.Remove the reverse clutch hub sub-assembly from the reverse clutch piston sub-assembly.

Remove the sleeve, cushion plate, flange, 5 discs and 4 plates from the reverse clutch piston sub-assembly.

Remove the reverse clutch flange from the reverse clutch piston sub-assembly.

1.Remove the thrust needle roller bearing from the direct clutch hub sub-assembly.

2.Remove the direct clutch hub sub-assembly from the reverse clutch piston sub-assembly.

3.Remove the thrust needle roller bearing and the thrust bearing race No. 2 from the direct clutch hub sub-assembly.

1.Remove the forward clutch sub-assembly from the reverse clutch drum sub-assembly.

2.Remove the thrust needle roller bearing and the thrust bearing race from the input shaft sub-assembly.

1.Remove the forward clutch hub from the input shaft sub-assembly.

2.Remove the thrust bearing race and the thrust needle roller bearing from the input shaft sub-assembly.

1.Using a screwdriver, remove the hole snap ring from the input shaft sub-assembly.

2.Remove the 2 flanges, 7 discs and 6 plates from the input shaft sub-assembly.

1.Set the special tools Spring compressor body (MD998903), as show in the illustration. 2. caution When compressing the forward clutch return spring sub-assembly, be careful not to brake it. Be careful not to expand the shaft snap ring too much. Using the special tool, remove the shaft snap ring.

3.Remove the forward clutch balancer and the forward clutch return spring sub-assembly from the input shaft sub-assembly.

Apply compressed air [392kPa (4kg/cm2)] into the oil passage as shown in the illustration and remove the forward clutch piston from the input shaft sub-assembly. note When applying compressed air, shut one oil passage of the input shaft sub-assembly as shown in the illustration.

Remove the 2 O-rings from the forward clutch piston. SIZE: O-ring Inner diameter (mm) Thickness (mm) 108.06 3.10 39.50 2.62

Remove the O-ring from the forward clutch balancer. SIZE: O-ring Inner diameter (mm) Thickness (mm) 107.40 2.62

Remove the 3 seal rings from the input shaft sub-assembly. SIZE: Seal ring Inner diameter (mm) Thickness (mm) 28.97 2.30

Using a screwdriver, remove the hole snap ring from the reverse clutch drum sub-assembly.

1.Using a screwdriver, remove the hole snap ring from the reverse clutch drum sub-assembly.

2.Remove the flange, 6 discs and 6 plates from the reverse clutch drum sub-assembly.

1.Set the special tools as show in the illustration. Retainer (MD998924) Spring compressor (MB991628) 2. caution Be careful not to expand the hole snap ring too much. Using the special tools, remove the shaft snap ring.

3.Remove the direct clutch balancer and the direct clutch return spring sub-assembly from the reverse clutch drum sub-assembly.

Apply compressed air [392kPa (4kg/cm2)] into the oil passage as shown in the illustration and remove the direct clutch piston from the reverse clutch drum sub-assembly. note When applying compressed air, shut one oil passage of the reverse clutch drum sub-assembly as shown in the illustration.

Remove the 2 O-rings from the direct clutch piston. SIZE: O-ring Inner diameter (mm) Thickness (mm) 126.70 3.10 74.70 2.62

1.Set the special tools as show in the illustration. Retainer (MD998924) Spring compressor (MB991628) 2. caution Be careful not to expand the shaft snap ring too much. Using the special tools, remove the shaft snap ring.

3.Remove the reverse clutch balancer and the reverse clutch return spring sub-assembly from the reverse clutch piston sub-assembly.

4.Remove the reverse clutch drum sub-assembly from the reverse clutch piston sub-assembly.

Remove the 2 O-rings from the reverse clutch piston sub-assembly. SIZE: O-Ring Inner diameter (mm) Thickness (mm) 142.30 3.10 139.50 3.10

Remove the O-ring from the reverse clutch drum sub-assembly. SIZE: O-ring Inner diameter (mm) Thickness (mm) 100.80 3.10

1.Coat a new O-ring with ATF. 2.Install the O-ring to the reverse clutch drum sub-assembly. SIZE: O-ring Inner diameter (mm) Thickness (mm) 100.80 3.10

1.Coat 2 new O-rings with ATF. 2.Install the O-rings to the reverse clutch piston sub-assembly. SIZE: O-ring Inner diameter (mm) Thickness (mm) 142.30 3.10 139.50 3.10

1.Coat the reverse clutch drum sub-assembly and the reverse clutch piston sub-assembly with ATF. 2. caution Be careful not to damage the O-rings. Install the reverse clutch drum sub-assembly to the reverse clutch piston sub-assembly.

1.Coat the reverse clutch drum sub-assembly and the reverse clutch balancer with ATF. 2. caution Be careful not to damage the O-ring. Install the reverse clutch return spring sub-assembly and the reverse clutch balancer to the reverse clutch piston sub-assembly.

1.Set the special tools as show in the illustration. Retainer (MD998924) Spring compressor (MB991628) 2. caution Be careful not to expand the shaft snap ring too much. Using the special tools, install the shaft snap ring.

1.Coat 2 new O-rings with ATF. 2.Install the O-rings to the direct clutch piston. SIZE: O-ring Inner diameter (mm) Thickness (mm) 126.70 3.10 74.70 2.62

1.Coat the direct clutch piston and the reverse clutch drum sub-assembly with ATF. 2. caution Be careful not to damage the O-ring. Install the direct clutch piston to the reverse clutch drum sub-assembly.

1.Coat the direct clutch balancer and the reverse clutch drum sub-assembly with ATF. 2. caution Be careful not to damage the O-ring. Install the direct clutch return spring sub-assembly and the reverse clutch balancer to the reverse clutch drum sub-assembly.

1.Set the special tools as show in the illustration. Retainer (MD998924) Spring compressor (MB991628) 2. caution Be careful not to expand the shaft snap ring too much. Using the special tools, install the shaft snap ring.

1.Coat the flange, 6 discs and 6 plates with ATF. 2. caution Check the number and order of the discs, plates and flange. Install the flange, 6 discs and 6 plates to the reverse clutch drum sub-assembly.

Using a screwdriver, install the hole snap ring to the reverse clutch drum sub-assembly.

Using a dial indicator, measure the moving distance (distance A) of the flange at the both ends across a diameter while applying compressed air [392kPa (4kg/cm2)] into the oil passage as shown in the illustration and calculate the average. Check that the piston moves smoothly. Standard value: 0.49 - 1.43 mm (For distance A) 0.6 - 0.9 mm (For direct clutch clearance) SIZE: Flange Flange Mark Thickness (mm) 2 2.95 - 3.05 3 3.05 - 3.15 4 3.15 - 3.25 5 3.25 - 3.35 6 3.35 - 3.45 7 3.45 - 3.55 8 3.55 - 3.65 9 3.65 - 3.75 A 3.75 - 3.85 note Direct clutch clearance = distance A - 0.19

Using a screwdriver, install the hole snap ring to the reverse clutch drum sub-assembly.

1.Coat the cushion plate, 2 flanges 5 discs and 4 plates with ATF. 2. caution Check the number and order of the discs, plates, flanges and cushion plate. Install the sleeve, cushion plate, 2 flanges 5 discs and 4 plates from the reverse clutch drum sub-assembly.

Using a screwdriver, install the hole snap ring to the reverse clutch piston sub-assembly.

Using a dial indicator, measure the reverse clutch piston sub-assembly stroke (distance A) and the moving distance (distance B) of the plate at the both ends across a diameter while applying compressed air [392kPa (4kg/cm2)] into the oil passage as shown in the illustration, and calculate the average. Check that the piston moves smoothly. Standard value: 1.69 - 2.81 mm (For distance A) 1.20 - 1.68 mm (For distance B) 0.5 - 0.8 mm (For reverse clutch clearance) SIZE: Flange Flange Mark Thickness (mm) 0 2.75 - 2.85 1 2.85 - 2.95 2 2.95 - 3.05 3 3.05 - 3.15 4 3.15 - 3.25 5 3.25 - 3.35 6 3.35 - 3.45 7 3.45 - 3.55 8 3.55 - 3.65 9 3.65 - 3.75 A 3.75 - 3.85 note Reverse clutch pack clearance = distance A - distance B - 0.16

Using a screwdriver, remove the hole snap ring from the reverse clutch piston sub-assembly.

Remove the sleeve, cushion plate, 2 flanges, 5 discs and 4 plates from the reverse clutch drum sub-assembly.

1.Coat 3 new seal rings and the sliding surface of the input shaft sub-assembly with ATF. 2. caution Be careful not to expand the seal rings too much. Be careful not to compress the seal rings too much, before installing the seal rings. Compress the 3 seal rings as shown in the illustration. Then install the seal rings to the input shaft sub-assembly. SIZE: Seal ring Inner diameter (mm) Thickness (mm) 28.97 2.30 note Check that the seal rings rotate smoothly after installing them.

1.Coat a new O-ring with ATF. 2.Install the O-ring to the forward clutch balancer. SIZE: O-ring Inner diameter (mm) Thickness (mm) 107.40 2.62

1.Coat a new O-ring with ATF. 2.Install the O-ring to the forward clutch piston. SIZE: O-ring Inner diameter (mm) Thickness (mm) 108.06 3.10 39.50 2.62

1.Coat the forward clutch piston, and input shaft sub-assembly with ATF. 2. caution Be careful not to damage the O-ring and oil rip. Install the forward clutch piston to the input shaft sub-assembly.

1.Coat the forward clutch balancer No. 1 and the input shaft sub-assembly with ATF. 2. caution Be careful not to damage the O-ring. Install the forward clutch return spring sub-assembly and the forward clutch balancer No. 1 to the input shaft sub-assembly.

1.Set the special tools Spring compressor body (MD998903), as show in the illustration. 2. caution When compressing the forward clutch return spring sub-assembly, be careful not to brake it. Be careful not to expand the shaft snap ring too much. Using the special tool, install the shaft snap ring.

1.Coat the 2 flanges, 7 discs and 6 plates with ATF. 2. caution Check the number and order of flanges, discs and plates. Install the 2 flanges, 7 discs and 6 plates to the input shaft sub-assembly.

Using a screwdriver, install the hole snap ring to the input shaft sub-assembly.

Using a dial indicator, measure the moving distance (distance A) of the flange at the both ends across a diameter while applying compressed air [196kPa (2kg/cm2)] into the oil passage as shown in the illustration, and calculate the average. Check that the piston moves smoothly. Standard value: 0.34 - 1.48 mm (For distance A) 0.8 - 1.0 mm (For forward clutch clearance) SIZE: Flange Flange Mark Thickness (mm) 0 2.95 - 3.05 1 30.5 - 3.15 2 3.15 - 3.25 3 3.25 - 3.35 4 3.35 - 3.45 5 3.45 - 3.55 6 3.55 - 3.65 7 3.65 - 3.75 8 3.75 - 3.85 9 3.85 - 3.95 A 3.95 - 4.05 note Forward clutch clearance = distance A - 0.01

1.Coat the thrust bearing race and the thrust needle roller bearing with ATF. 2.Install the thrust bearing race and the thrust needle roller bearing to the input shaft sub-assembly.

3.Install the forward clutch hub to the input shaft sub-assembly.

1.Coat the thrust needle roller bearing and the thrust bearing race with ATF. 2.Install the thrust needle roller bearing and the thrust bearing race to the input shaft sub-assembly.

3.Install the forward clutch sub-assembly to the reverse clutch drum sub-assembly.

1.Coat the thrust needle roller bearing and the thrust bearing race with ATF. 2.Install the thrust bearing race No. 2 and the thrust needle roller bearing to the direct clutch hub sub-assembly.

3.Install the direct clutch hub sub-assembly to the reverse clutch piston sub-assembly.

1.Coat the thrust needle roller bearing with ATF. 2.Install the thrust needle roller bearing to the direct clutch hub sub-assembly.

1.Coat the flange with ATF. 2.Install the flange to the reverse clutch piston sub-assembly.

Install the reverse clutch hub sub-assembly to the reverse clutch piston sub-assembly.

1.Coat the cushion plate, flange, 5 discs and 4 plates with ATF. 2. caution Check the number and order of the discs, plates, flange and cushion plate. Install the sleeve, cushion plate, flange, 5 discs and 4 plates to the reverse clutch piston sub-assembly.

Using a screwdriver, install the hole snap ring to the reverse clutch piston sub-assembly.