Clutch Drum And Input Shaft Assembly: Reassembly

1. Coat 2 new O-rings with ATF, and install them in the direct clutch piston.
   Fig 1: Identifying Direct Clutch Piston O-Rings

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2. Install the No. 2 clutch balancer and the direct clutch return spring to the direct clutch piston sub-assembly.
3. Press the direct clutch piston into the clutch drum.
   Fig 2: Identifying Clutch Balancer Return Spring Sub Assembly & Direct Clutch Piston Sub Assembly

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   NOTE: Do not damage the 2 O-rings.
4. Place SST on the No. 2 clutch balancer, and compress the return spring with a press.

   SST 09350-30020 (09350-07070), 09518-36020 

5. Install the snap ring with a snap ring expander.
   NOTE:

   • Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
   • Stop pressing when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring seat from being deformed.
   • Do not expand the snap ring excessively.
   Fig 3: Installing Snap Ring With Snap Ring Expander

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6. Set the end gap of the snap ring in the piston.

Fig 4: Setting End Gap Of Snap Ring In Piston

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1. Coat a new O-ring with ATF, and install it on the reverse clutch drum sub-assembly.
   Fig 5: Identifying Clutch Drum O-Ring

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2. Coat a new O-ring with ATF, and install it on the reverse clutch piston sub-assembly.
   Fig 6: Identifying Reverse Clutch Piston Sub-Assembly O-Ring

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3. Press the reverse clutch drum sub-assembly into the reverse clutch piston.

Fig 7: Identifying Reverse Clutch Drum Sub-Assembly & Reverse Clutch Piston

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1. Coat a new O-ring with ATF, and install it on the reverse clutch piston sub-assembly.
2. Install the reverse clutch return spring onto the reverse clutch piston sub-assembly.

Fig 8: Identifying O-Ring On Reverse Clutch Piston Sub-Assembly

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1. Place the No. 3 clutch balancer on the return spring.
2. Place SST on the No. 3 clutch balancer, and compress the clutch balancer with a press.

   SST 09387-00050, 09387-00070 

   Fig 9: Installing Clutch Balancer No. 3 Snap Ring (1 Of 2)

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3. Install the snap ring with a snap ring expander.

   SST 09350-30020 (09350-07070) 

   NOTE:

   • Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
   • Stop pressing when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring seat from being deformed.
   • Do not expand the snap ring excessively.
4. Set the end gap of the snap ring in the piston.

Fig 10: Installing Clutch Balancer No. 3 Snap Ring (2 Of 2)

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1. Install the reverse clutch flange, the 5 plates and the 4 discs on the reverse clutch drum sub-assembly.

   Install in order: 

   P = Plate, D = Disc, F = Flange, F - D - P - D - P - D - P - D - P - P 

   Fig 11: Installing Reverse Clutch Flange, Plates & Discs On Reverse Clutch Drum Sub-Assembly

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2. Using a screwdriver, install the 2 hole snap rings on the reverse clutch drum sub-assembly.

1. Install the reverse clutch flange to the reverse clutch drum sub-assembly.

Fig 13: Installing Reverse Clutch Flange

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1. Install the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 5 reverse clutch discs, and the 4 clutch plates to the reverse clutch hub.

   Install in order: 

   P = Plate, D = Disc, F = Flange, S = Sleeve, C = Cushion Plate 

   S - C - F - D - P - D - P - D - P - D - P - D 

2. Using a screwdriver, install the hole snap ring.

1. Using a screwdriver, remove the snap ring from the reverse clutch drum sub-assembly.
   Fig 15: Removing Snap Ring From Reverse Clutch Drum Sub-Assembly

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

Fig 16: Removing Reverse Clutch Discs & Clutch Plates From Reverse Clutch Hub Sub-Assembly

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1. Install the coast clutch piston to the forward clutch piston.
2. Coat a new O-ring with ATF and install it on the forward clutch piston.
3. Install the forward clutch piston sub-assembly to the input shaft.

Fig 17: Identifying Coast Clutch Piston & Forward Clutch Piston

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1. Coat a new D-ring with ATF and install it on the No. 1 clutch balancer.
   Fig 18: Installing D-Ring On No. 1 Clutch Balancer

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2. Install the No. 1 clutch balancer and the forward clutch return spring sub-assembly.
   NOTE: Do not damage the D-ring.
   Fig 19: Installing No. 1 Clutch Balancer & Forward Clutch Return Spring Sub-Assembly

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3. Place SST on the No. 1 clutch balancer, and compress the return spring with a press.

   SST 09350-30020 (09350-07040, 09350-07070) 

4. Install the snap ring with a snap ring expander.
   Fig 20: Installing Snap Ring With Snap Ring Expander

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   NOTE:

   • Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
   • Stop pressing when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring seat from being deformed.
   • Do not expand the snap ring excessively.
5. Set the end gap of the snap ring in the piston.

Fig 21: Setting End Gap Of Snap Ring In Piston

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1. Install the flange, the 3 discs and the 3 plates to the forward clutch piston.
2. Using a screwdriver, install the hole snap ring.

1. Install the flange, the 4 discs, 4 plates and clutch cushion plate to the input shaft assembly.

   Install in order: 

   P = Plate, D = Disc, F = Flange, C = Cushion Plate 

   F - D - P - D - P - D - P - D - P - C 

   Fig 23: Installing Flange, Discs, Plates & Clutch Cushion Plate To Input Shaft Assembly

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2. Using a screwdriver, install the hole snap ring.
   Fig 24: Installing Hole Snap Ring

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3. Install the thrust needle roller bearing and the thrust bearing race.

Fig 25: Installing Thrust Needle Roller Bearing & Thrust Bearing Race

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1. Coat 4 new oil seal rings with ATF.
2. Squeeze the ends of the 4 oil seal rings together, and then install them to the starter shaft groove.

Fig 26: Identifying Oil Seal Rings

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HINT:

After installing the oil seal rings, check that they rotate smoothly.

1. Install the input shaft assembly to the reverse clutch drum sub-assembly.
   Fig 27: Identifying Input Shaft Assembly & Clutch Drum

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2. Install the thrust needle roller bearing to the reverse clutch drum sub-assembly.

Thrust needle roller bearing diameter 

Fig 28: Installing Thrust Needle Roller Bearing To Reverse Clutch Drum Sub-Assembly

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1. Install the clutch hub thrust washer and the input shaft rear thrust bearing race to the coast clutch hub.

   Bearing and race diameter 

   BEARING AND RACE DIAMETER SPECIFICATIONS
   
   

   -	Inside	Outside
   Input shaft rear thrust bearing race	22.6 mm (0.890 in.)	44.8 mm (1.764 in.)

   Fig 29: Installing Clutch Hub Thrust Washer & Input Shaft Rear Thrust Bearing Race To Coast Clutch Hub

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2. Install the coast clutch hub sub-assembly to the reverse clutch drum sub-assembly.

Fig 30: Identifying Coast Clutch Hub Sub-Assembly

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1. Install the 2 thrust needle roller bearings and No. 3 thrust bearing race to the clutch hub sub-assembly.

   Bearing and race diameter 

   BEARING AND RACE DIAMETER SPECIFICATIONS
   
   

   -	Inside	Outside
   Bearing A	42.5 mm (1.673 in.)	61.2 mm (2.409 in.)
   Bearing B	35.6 mm (1.402 in.)	56.6 mm (2.228 in.)

   Fig 31: Installing Thrust Needle Roller Bearings & No. 3 Thrust Bearing Race To Clutch Hub Sub-Assembly

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2. Install the forward clutch hub sub-assembly and clutch hub thrust washer to the reverse clutch drum sub-assembly.

Fig 32: Identifying Clutch Hub Thrust Washer, Forward Clutch Hub Sub-Assembly & Clutch Drum Assembly

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1. Install the clutch cushion plate, the reverse clutch flange, the 4 plates and the 5 discs to the reverse clutch hub.

Fig 33: Installing Clutch Cushion Plate, Reverse Clutch Flange, Plates & Discs To Reverse Clutch Hub

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1. Install the reverse clutch reaction sleeve to the reverse clutch hub.

Fig 34: Installing Reverse Clutch Reaction Sleeve To Reverse Clutch Hub

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1. Install the reverse clutch hub sub-assembly with the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 5 reverse clutch discs, and the clutch plates to the reverse clutch drum sub-assembly.
   Fig 35: Identifying Reverse Clutch Hub Sub-Assembly & Reverse Clutch Drum Sub-Assembly

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2. Using a screwdriver, install the snap ring on the reverse clutch drum sub-assembly and the input shaft assembly.

Fig 36: Installing Clutch Drum & Input Shaft Assembly Snap Ring

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