Direct & Reverse Clutch: Reassembly
WARNING: This page is about a different variant/trim than selected.
- Install NEW "O" rings on direct clutch drum and piston. Coat piston with ATF. Install direct clutch drum into intermediate shaft housing. Using hand pressure, press piston into direct clutch drum. Ensure piston lip seal is not damaged. Install piston return springs onto direct clutch drum. Set snap ring in position.
- Using appropriate press positioned on piston return spring seat, compress piston return springs. Using snap ring expander, install snap ring.
- Install 3 plates and 3 discs, starting with plate and alternating with disc. Install flange on top of disc. Install direct clutch snap ring. On U340E transaxle, install 2 discs and 2 plates, starting with plate and alternating with disc. Install flange. On U341E transaxle, install, 3 discs and 3 plates, starting with plate and alternating with disc. Install flange. On both transaxles, install snap ring. See Figure.
- Check reverse clutch pack clearance. Install direct and reverse clutch assembly, and thrust needle roller bearing on transaxle rear cover. Using a dial indicator, measure reverse clutch pack clearance by applying and releasing 57 psi (4 kg/cm2 ) of compressed air to transaxle rear cover. See Fig 1.
- Clutch pack clearance should be .034-.050" (.86-1.26 mm). If clutch pack clearance is not within specification, disassemble and reassemble reverse clutch components.
- Measure clutch pack clearance again. If measurement is still not within specification, replace flange. Flange is available in 4 thicknesses, from .118" (3.00 mm) to .142" (3.60 mm) in increments of .008" (.20 mm).
- Measure direct clutch pack clearance. Using a dial indicator and adapter, measure direct clutch pack clearance by applying and releasing 57 psi (4 kg/cm2 ) of compressed air to transaxle rear cover. See Fig 2.
- Clutch pack clearance should be .024-.040" (.62-1.02 mm). If clutch pack clearance is not within specification, disassemble and reassemble direct clutch components.
- Measure clutch pack clearance again. If measurement is still not within specification, replace flange. Flange is available in 4 thicknesses, from .118" (3.00 mm) to .142" (3.60 mm) in increments of .008" (.20 mm).
CAUTION:
In the following step, do not compress piston return spring more than .079" (2.00 mm) past snap ring groove. This prevents piston from becoming deformed. DO NOT expand snap ring excessively.
NOTE:
In the following step, direct and reverse clutch assembly may raise intermediate shaft housing as compressed air is applied. To ensure accurate clutch pack clearance reading, secure assembly in appropriate press prior to applying pressure to transaxle rear cover to secure intermediate shaft housing to transaxle rear cover.