Page 65 of 2389

AT7710 AT2733
SST
AT3617
Plate DiscFlange
AT0171
AT7709
SST
(b) Place SST on the spring retainer, and compress
the return spring with a shop press.
SST 09350-32014 (09351-32070)
(c) Install the snap ring using snap ring pliers. Be
sure the end gap of snap ring is not aligned with
the spring retainer claw.
3. INSTALL PLATES, DISCS AND FLANGE
(a) Install plates and discs.
Install in order: P = Plate D = Disc
P-D-P-D-P-D
(b) Install the flange with the flat end facing downward.
4. INSTALL SNAP RING
Check that the end gap of the snap ring is not aligned
with one of the cutouts.
5. RECHECK PISTON STROKE OF DIRECT CLUTCH
(a) Install the direct clutch on the oil pump.
(b) Using a dial indicator (long type pick or SST),
measure the direct clutch piston stroke applying
and releasing the compressed air (4 - 8 kg/cm
2,
57 - 114 psi, 392 - 785 kPa) as shown.
SST 09350-32014 (09351-32190)
Piston stroke: A540E 0.91 - 1.35 mm
(0.0358 - 0.0531 in.)
A540H 1.11 - 1.47 mm
(0.0437 - 0.0579 in.)
If the piston stroke is nonstandard, select another
flange.
HINT: There are two different thicknesses for the
flange.
Flange thickness: 2.70 mm (0.1063 in.)
3.00 mm (0.1181 in.)
AT-50- AUTOMATIC TRANSAXLEComponent Parts (Direct Clutch)
Page 66 of 2389
AT3619
SST
AT3620
A540E
AT4342Plate r Non-reusable partFlangeSnap Ring DiscSpring
Retainer A540HSnap Ring Oil Seal
RingClutch Drum BearingPistonBearingr O-RingReturn
Spring
A540H
Forward Clutch
COMPONENTS
DISASSEMBLY OF FORWARD CLUTCH
1. CHECK PISTON STROKE OF FORWARD CLUTCH
Using a dial indicator (long type pick or SST), measure
the forward clutch piston stroke applying and releasing
the compressed air (4 - 8 kg/cm
2, 57 - 114 psi, 392 -
785 kPa) as shown.
SST 09350-32014 (09351-32190)
Piston stroke: 1.41 - 1.82 mm
(0.0555 - 0.0717 in.)
If the piston stroke is greater than the maximum, inspect
each component.
- AUTOMATIC TRANSAXLEComponent Parts (Forward Clutch)AT-51
Page 67 of 2389
A70176
AT2738
AT0177
SST
AT3621
A540E
AT4341
A540H
2. REMOVE SNAP RING FROM CLUTCH DRUM
3. REMOVE FLANGE, DISCS AND PLATES
4. REMOVE RETURN SPRING
(a) Place SST on the spring retainer and compress the
springs with a shop press.
SST 09350-32014 (09351-32070)
(b) Remove the snap ring using snap ring pliers.
(c) (A540E)
Remove the return spring.
AT-52- AUTOMATIC TRANSAXLEComponent Parts (Forward Clutch)
Page 68 of 2389
AT2797
A540HSpring Retainer
AT4572
A540H
AT2735
AT3623
Oil Seal Ring A540E
AT3622
A540E
(A540H)
Remove the spring retainer and eighteen return
springs.
5. REMOVE CLUTCH PISTON
(a) Apply compressed air into the oil passage to re-
move the piston.
If the piston does not come out, use needle-nose pliers
to remove it.
(b) Remove the two O-rings from the piston.
6. IF NECESSARY, REMOVE OIL SEAL RINGS
(A540E)
Remove the three oil seal rings from the shaft.
- AUTOMATIC TRANSAXLEComponent Parts (Forward Clutch)AT-53
Page 69 of 2389

AT0179 AT0180
AT7712
Printed
Numbers
AT4499
Oil Seal Ring
A540H A540E
AT2736 AT4340
Oil Seal Ring A540H
(A540H)
Remove the two oil seal rings from the shaft.
INSPECTION OF FORWARD CLUTCH
1. INSPECT CLUTCH PISTON
(a) Check that the check ball is free by shaking the
piston.
(b) Check that the valve does not leak by applying
low-pressure compressed air.
2. INSPECT DISCS, PLATES AND FLANGE
Check if the sliding surfaces of the discs, plates and
flange are worn or burnt. If necessary, replace them.
HINT:
If the lining of the disc is exfoliated or discolored, or
even a part of the printed numbers are defaced,
replace all discs.
Before assembling new discs, soak them in ATF for
at least fifteen minutes.
ASSEMBLY OF FORWARD CLUTCH
1. INSTALL OIL SEAL RINGS
Install the three oil seal rings (A540E) or two oil seal
rings (A540H) to the shaft.
NOTICE: Do not spread the ring ends more than nec-
essary.
HINT: After installing the oil seal rings, check that they
move smoothly.
2. INSTALL CLUTCH PISTON TO CLUTCH DRUM
(a) Install the two new O-rings to the piston.
AT-54- AUTOMATIC TRANSAXLEComponent Parts (Forward Clutch)
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A70177
SST
AT3624
Plate DiscFlange
AT7713
AT3619
SST
AT0182
(b) Coat the O-rings with ATF.
(c) Press the piston into the drum with the cup side
up, being careful not to damage the O-rings.
3. INSTALL PISTON RETURN SPRINGS
(a) Place the return spring and snap ring onto the
piston.
(b) Place SST on the spring retainer, and compress
the springs with a shop press.
SST 09350-32014 (09351-32070)
(c) Install the snap ring with snap ring pliers.
Be sure the end gap of the snap ring is not
aligned with the spring retainer claw.
4. INSTALL PLATES, DISCS AND FLANGE
(a) Install the plates and discs.
Install in order: P = Plate D = Disc
P-D-P-D-P-D-P-D
(b) Install the flange with the flat end facing downward.
5. INSTALL SNAP RING
Check that the end gap of snap ring is not aligned with
one of the cutouts.
6. RECHECK PISTON STROKE OF FORWARD CLUTCH
Using a dial indicator (long type pick or SST), measure
the forward clutch piston stroke applying and releasing
the compressed air (4 - 8 kg/cm
2, 57 - 114 psi, 392 -
785 kPa) as shown next page.
SST 09350-32014 (09351-32190)
Piston stroke: 1.41 - 1.82 mm
(0.0555 - 0.0717 in.)
- AUTOMATIC TRANSAXLEComponent Parts (Forward Clutch)AT-55
Page 71 of 2389
AT3620
A540E
AT4341
A540H
If the piston stroke is nonstandard, select another flange.
HINT: There are two different thicknesses for the flange.
Flange thickness: 3.00 mm (0.1181 in.)
3.37 mm (0.1327 in.)
AT-56- AUTOMATIC TRANSAXLEComponent Parts (Forward Clutch)
Page 72 of 2389
AT3747
Snap RingBearingBearingSnap RingNo. 1 One-Way Clutch Ring Gear FlangeRing GearPlanetary GearSun GearSun Gear
Input DrumThrust WasherThrust Washer
(A540E only)
AT0185
Turn Free HoldLock
AT0186
Front Planetary Gear
COMPONENTS
DISASSEMBLY OF NO. 1 ONE-WAY CLUTCH
AND SUN GEAR
1. CHECK OPERATION OF NO. 1 ONE-WAY CLUTCH
Hold the sun gear and turn the hub. The hub should
turn freely clockwise and should lock counterclockwise.
2. REMOVE NO. 1 ONE-WAY CLUTCH FROM SUN
GEAR
While turning the hub clockwise, remove the No. 1
one-way clutch from the sun gear.
- AUTOMATIC TRANSAXLEComponent Parts (Front Planetary Gear)AT-57