Page 5913 of 6000
7A–132 AUTOMATIC TRANSMISSION (AW30-40LE)
252RY00042
252RY00043
Check OD brake piston
Place the OD suppor t assembly onto the direct clutch
assembly.
Apply compressed air into the oil passage as shown, and be
sure that the OD brake piston moves smoothly.
Page 5914 of 6000
AUTOMATIC TRANSMISSION (AW30-40LE) 7A–133
DIRECT CLUTCH ASSEMBLY (C-2)
DISASSEMBLY
248RY00059
Disassembly steps
1. Clutch drum thrust washer
2. Snap ring
3. Flange
4. Plate and disc
5. Snap ring
6. Piston return spring
7. Direct clutch piston
8. O-ring
Page 5915 of 6000
7A–134 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00028
248RY00029
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248RY00002
Important operations
Remove direct clutch drum assembly from forward clutch
assembly.
Check piston stroke of direct clutch (C-2)
Place the direct clutch assembly onto the OD suppor t
assembly.
Using a dial indicator, measure the direct clutch piston
stroke by applying and releasing compressed air (4– 8 kg/
cm
2, 57– 114 psi or 392– 785 kPa) as shown.
5. Snap ring
Place special tool and a suitable ring on the spring retainer
and compress the return spring. Using snap ring pliers,
remove the snap ring.
Spring compressor: 5-8840-0254-0 (J-25048)mm (in.)
Piston stroke1.6– 1.9
(0.0630– 0.0748)
Page 5916 of 6000
AUTOMATIC TRANSMISSION (AW30-40LE) 7A–135
248RY00030
247RY00034
252RY00027
248RY00031
7. Direct clutch piston
Place the direct clutch drum onto the OD support.
Holding the direct clutch piston by hand, apply compressed
air to the OD support to remove the direct clutch piston.
Remove the direct clutch piston.
Remove two O-ring from piston.
INSPECTION AND REPAIR
Check piston return spring
Using calipers, measure the free length of the return spring.
Check discs
Using a micrometer, measure the thickness of the discs.
If the thickness is less than the minimum, replace the disc.
Check direct clutch piston
Check that check ball is free by shaking the piston.
Check that the valve does not leak by applying low-pressure
compressed air.mm (in.)
Standard 21.3 (0.839)
mm (in.)
Minimum thickness 1.84 (0.0724)
Page 5917 of 6000
7A–136 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00032
Check direct clutch drum bushing
Using a dial indicator, measure the inside diameter of the
clutch drum bushing.
If the inside diameter is grater than maximum, replace the
clutch drum.mm (in.)
Maximum inside diameter 53.99 (2.1256)
Page 5918 of 6000
AUTOMATIC TRANSMISSION (AW30-40LE) 7A–137
REASSEMBLY
248RY00060
Reassembly steps
1. O-ring
2. Direct clutch piston
3. Piston retur n spring
4. Snap ring
5. Disc and plate
6. Flange
7. Snap ring.
8. Clutch drum thrust washer (plastic)
Page 5919 of 6000
7A–138 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00033
248RY00034
248RY00002
248RY00062
Important operations
1. O-ring
Coat new O-rings with ATF and install them on the direct
clutch piston.
2. Direct clutch piston
Install direct clutch piston to direct clutch drum.
Being careful not to damage the O-rings, press in the direct
clutch piston into the clutch drum, using both hands.
3. Piston return spring
Install piston return spring.
4. Snap ring
Compress piston return spring and install snap ring in
groove.
Place special tool and a suitable ring on the spring retainer,
and compress the return spring.
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.
Spring compressor: 5-8840-0254-0 (J-25048)
5. Disc and plate
Install plates and discs.
Install in order: P– D– P– D– P– D– P– D– P– D
P: Plate, D: Disc
Page 5920 of 6000
AUTOMATIC TRANSMISSION (AW30-40LE) 7A–139
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6. Flange
Install the flange, with the flat side facing downward.
7. Snap ring
Install the snap ring with a screwdriver. Be sure the end
gap of the snap ring is not aligned with the cutout portion of
the direct clutch drum.
Check piston stroke of direct clutch (C-2)
Place the direct clutch assembly onto the OD suppor t
assembly.
Using a dial indicator, measure the direct clutch piston
stroke by applying and releasing compressed air (4– 8 kg/
cm
2, 57– 114 psi or 392– 785 kPa) as shown.
If the piston stroke is not within specification, replace the
discs and recheck the piston stroke.
If the piston stroke is non standard, select another flange.
There are eight flanges.mm (in.)
Piston stroke1.6– 1.9
(0.0630– 0.0748)
mm (in.)
No. Flange thickness No. Flange thickness
33 3.3 (0.130) 37 3.7 (0.146)
34 3.4 (0.134) 38 3.8 (0.150)
35 3.5 (0.138) 39 3.9 (0.154)
36 3.6 (0.142) 40 4.0 (0.158)