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 
22551-RPC-003 2.1 mm (0.083 in.) 
22552-RPC-003 2.2 mm (0.087 in.) 
22553-RPC-003 2.3 mm (0.091 in.) 
22554-RPC-003 2.4 mm (0.094 in.) 
22555-RPC-003 2.5 mm (0.098 in.) 
22556-RPC-003 2.6 mm (0.102 in.) 
22557-RPC-003 2.7 mm (0.106 in.) 
22558-RPC-003 2.8 mm (0.110 in.) 
22559-RPC-003 2.9 mm (0.114 in.) 

3RD and 5TH CLUTCH END-PLATES
Mark Part Number Thickness 
22561-RPC-003 2.1 mm (0.083 in.) 
22562-RPC-003 2.2 mm (0.087 in.) 
22563-RPC-003 2.3 mm (0.091 in.) 
22564-RPC-003 2.4 mm (0.094 in.) 
22565-RPC-003 2.5 mm (0.098 in.) 
22566-RPC-003 2.6 mm (0.102 in.) 
22567-RPC-003 2.7 mm (0.106 in.) 
22568-RPC-003 2.8 mm (0.110 in.) 
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.