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Forward Clutch: Reassembly

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CAUTION: Forward clutch piston seal may be damaged during installation. Carefully install forward clutch piston by pushing evenly around circumference.
    CAUTION: Depress seal plate only enough to install snap ring.
  1. Apply ATF to all components. Install piston into forward clutch drum and turbine shaft. Install spring and retainer assembly. Install seal plate onto forward clutch drum. Compress seal plate. Install snap ring. Install drive and driven plates in alternate order, beginning with drive plate.
  2. Measure forward clutch clearance. Install forward clutch in oil pump. Set dial gauge. Place forward clutch on press and secure with light pressure. See Fig 1.
  3. Apply 57-63 psi (4.0-4.4 kg/cm2 ) of compressed air to forward clutch fluid passage and allow forward clutch piston to stroke 3 times. Using dial indicator, measure piston stroke. Apply compressed air and operate forward clutch piston. Read value when indicator of dial gauge stops. Release compressed air. Read dial gauge when forward clutch piston is not operating. Subtract second value from first value to obtain forward clutch clearance.
  4. Repeat step  3 at 4 locations (90 degrees apart). Ensure average value is 0.059-0.070" (1.50-1.80 mm). See TRANSAXLE SPECIFICATIONS . If clearance is not within specification, remove snap ring and measure thickness. Add snap ring thickness to average forward clutch clearance. Select appropriate sized snap ring to obtain proper clearance. See FORWARD CLUTCH SNAP RING SIZES  table.
  5. Install snap ring. Perform steps  2- 4 to verify calculated value is within specification.
  6. Install forward clutch drum and turbine shaft to oil pump. Apply compressed air to fluid passage. Ensure air flow is present. Install forward clutch hub.
FORWARD CLUTCH SNAP RING SIZES

Range - In. (mm) Snap Ring Sizes - In. (mm)
.108-.116 (2.75-2.95) .047 (1.20)
.116-.124 (2.95-3.15) .055 (1.40)
.124-.132 (3.15-3.35) .063 (1.60)
.132-.140 (3.35-3.55) .071 (1.80)
.140-.148 (3.55-3.75) .079 (2.00)
.148-.155 (3.75-3.95) .087 (2.20)
Fig 1: Measuring Forward Clutch Piston Stroke
G00024926Courtesy of MAZDA MOTORS CORP.
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