Direct Clutch Disassembly & Reassembly: Reassembly

Install NEW "O" rings on piston. Coat rings with ATF. Press piston in drum with cup side up. Ensure "O" ring is not damaged. Install piston return springs. Install retainer and snap ring.
Install plates, discs and flange. Install flange with flat side facing inward. Install outer snap ring. Ensure end gap of snap ring is not aligned with cut-outs in direct clutch drum.
Install direct clutch on oil pump. Check piston stroke. Using a dial indicator, measure piston stroke by applying and releasing 57-114 psi (4-8 kg/cm² ) of compressed air. See Fig 1.
Piston stroke should be .036-.053" (.91-1.35 mm) for A-540E and A-541E transaxles or .044-.058" (1.11-1.47 mm) for A-540H transaxle. If piston stroke is less than specification, replace flange. Flange is available in thicknesses of .106" (2.70 mm) and .118" (3.00 mm) for A-540E and A-541E transaxles or .102" (2.60 mm), .110" (2.80 mm) and .118" (3.00 mm) for A-540H transaxle.

Fig 1: Checking Direct Clutch Piston Stroke

Fig 2: Exploded View Of Direct Clutch