Direct Clutch & Output Shaft Assembly Inspection
Check direct clutch disc set for burn, damage, deformation or discoloration. When there is anything faulty, replace it.
Measure free length “a” of direct clutch piston return spring.
When measured value is less than specified value, replace it.
Free length “a” includes spring seat (1) thickness.
Direct clutch return spring free length
“a”: 28.14 mm (1.108 in.)
Check seals (1) around direct clutch balancer (2) and direct clutch piston (3) for any damage. When there is anything faulty, replace it.
Measure inner diameter “a” of output shaft bush. When measured value exceeds limit value, replace output shaft.
Output shaft bush bore
Limit “a”: 23.35 mm (0.919 in.)
Piston Stroke Check
1) Install direct clutch disc set (1) (4 friction plates, 4 friction discs and separator plate) to intermediate shaft (2), then install snap ring (3).
2) Blow air into oil passage (4) in intermediate shaft (2) and measure piston stroke “a”, using special tool. When measured value is out of specified value range, change thickness of separator plate (5) to obtain specified value, then measure piston stroke “a” again.
Special Tool
(A) : 09952–06010
Direct clutch piston stroke
“a”: 0.6 – 0.9 mm (0.024 – 0.035 in.)
Available direct clutch separator plate thickness
3.35 mm (0.132 in.)
3.15 mm (0.124 in.)
2.95 mm (0.116 in.)
2.75 mm (0.108 in.)