A/T Clutch Clearance Inspection

Special Tools Required
Clutch compressor attachment (  07ZAE-PRP0100)
 

1.	Inspect the clutch piston, discs, plates, and end-plate for wear and damage, and inspect the clutch waved-plate phase difference, if necessary.

2.	Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch waved-plate, alternately install the waved-plates (C) (6) and discs (D) (6). Install the clutch end-plate (E) with the flat side down on the top disc.

3.	Install the clutch pistons in the 2nd, 3rd, 4th, and 5th clutch drums. Do not install the O-rings during inspection.

4.	Install the waved spring (A) in the 2nd clutch drum (B). Starting with the clutch flat-plate, alternately install the flat-plates (C) (4) and discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.

5.	Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch flat-plate, alternately install the flat-plates (C) (4) and discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.

6.	Install the waved spring (A) in the 3rd clutch drum (B). Starting with the clutch waved-plate, alternately install the waved-plates (C) (4) and discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.

7.	Install the waved spring (A) in the 5th clutch drum (B). Starting with the clutch waved-plate, alternately install the waved-plates (C) (4) and discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.

8.	Install the snap ring with a screwdriver to secure the clutch end-plate.

9.	Set a dial indicator (A) on the clutch end-plate (B).

10.	Zero the dial indicator with the clutch end-plate lifted up to the snap ring (C).

11.	Release the clutch end-plate to lower the clutch end-plate, then put the special tool on the end-plate (A).

12.

For the 1st, 3rd, and 5th clutches: Press the special tool down with 150-160 N (15-16 kgf, 33-35 lbf) (B) using a force gauge, and read the dial indicator (C). The dial indicator reads the clearance (D) between the clutch-end-plate and top disc (E). Take measurements in at least three places, and use the average as the actual clearance.

13.

For 2nd and 4th clutches: Press the special tool down with 39 N (4 kgf, 9 lbf) (B) using a force gauge, and read the dial indicator (C). The dial indicator reads the clearance (D) between the clutch-end-plate and top disc (E). Take measurements in at least three places, and use the average as the actual clearance. Clutch End-Plate-to-Top-Disc Clearance Service Limit  1st clutch:  1.62-1.82 mm (0.064-0.072 in.)  2nd clutch:  0.7-0.9 mm (0.028-0.035 in.)  3rd clutch:  0.93-1.13 mm (0.037-0.044 in.)  4th clutch:  0.7-0.9 mm (0.028-0.035 in.)  5th clutch:  0.93-1.13 mm (0.037-0.044 in.)

14.

If the clearance of the 1st, 3rd, or 5th clutch is out of the service limit, select a new clutch end-plate from the following table.   1ST CLUTCH END-PLATES Mark  Part Number  Thickness  1  22551-RPC-003  2.1 mm (0.083 in.)  2  22552-RPC-003  2.2 mm (0.087 in.)  3  22553-RPC-003  2.3 mm (0.091 in.)  4  22554-RPC-003  2.4 mm (0.094 in.)  5  22555-RPC-003  2.5 mm (0.098 in.)  6  22556-RPC-003  2.6 mm (0.102 in.)  7  22557-RPC-003  2.7 mm (0.106 in.)  8  22558-RPC-003  2.8 mm (0.110 in.)  9  22559-RPC-003  2.9 mm (0.114 in.)  3RD and 5TH CLUTCH END-PLATES Mark  Part Number  Thickness  1  22561-RPC-003  2.1 mm (0.083 in.)  2  22562-RPC-003  2.2 mm (0.087 in.)  3  22563-RPC-003  2.3 mm (0.091 in.)  4  22564-RPC-003  2.4 mm (0.094 in.)  5  22565-RPC-003  2.5 mm (0.098 in.)  6  22566-RPC-003  2.6 mm (0.102 in.)  7  22567-RPC-003  2.7 mm (0.106 in.)  8  22568-RPC-003  2.8 mm (0.110 in.)  9  22569-RPC-003  2.9 mm (0.114 in.)

15.

If the clearance of the 2nd or 4th clutch is out of the service limit, remove the clutch end-plate and check the clutch end-plate mark. Select a new clutch end-plate from the following tables by the mark on the old clutch end-plate; use the AC-AL Plates table with the old clutch end-plate is marked with between AC and AL, and use the AM-AV Plates table with the old clutch end-plate is marked with between AM and AV.   2ND and 4TH CLUTCH END-PLATES AC-AL Plates Mark  Part Number  Thickness  AC  22551-RPC-004  2.1 mm (0.083 in.)  AD  22552-RPC-004  2.2 mm (0.087 in.)  AE  22553-RPC-004  2.3 mm (0.091 in.)  AF  22554-RPC-004  2.4 mm (0.094 in.)  AG  22555-RPC-004  2.5 mm (0.098 in.)  AH  22556-RPC-004  2.6 mm (0.102 in.)  AJ  22557-RPC-004  2.7 mm (0.106 in.)  AK  22558-RPC-004  2.8 mm (0.110 in.)  AL  22559-RPC-004  2.9 mm (0.114 in.)  AM-AV Plates Mark  Part Number  Thickness  AM  22561-RPC-004  2.1 mm (0.083 in.)  AN  22562-RPC-004  2.2 mm (0.087 in.)  AP  22563-RPC-004  2.3 mm (0.091 in.)  AQ  22564-RPC-004  2.4 mm (0.094 in.)  AR  22565-RPC-004  2.5 mm (0.098 in.)  AS  22566-RPC-004  2.6 mm (0.102 in.)  AT  22567-RPC-004  2.7 mm (0.106 in.)  AU  22568-RPC-004  2.8 mm (0.110 in.)  AV  22569-RPC-004  2.9 mm (0.114 in.)

16.	Install the new clutch end-plate, and recheck the clearance. If the thickest clutch end-plate is installed, but the clearance is still over the service limit, replace the clutch discs and plates.