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 clutch waved-plate phase difference, if necessary.

2.Install the clutch piston in the clutch drum. Do not install the O-rings during inspection.

 

3.Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch waved-plates (C) (4), and discs (D) (4), and install the clutch end-plate (E) with the flat side down on the top disc.

 

4.Install the waved spring (A) in the 2nd clutch drum (B). Install the clutch flat-plate (C), and clutch disc (D). Starting with the clutch waved-plate, alternately install the clutch waved-plates (E) (3), and discs (F) (3), and install the clutch end-plate (G) with the flat side down on the disc.

 

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

 

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

 

8.Install the snap ring with a screwdriver.

 

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.Press the special tool down with 150-160 N (15-16 kgf, 33-35 lbf) using a force gauge, and read the dial indicator (B).

13.The dial indicator reads the clearance (C) between the clutch end-plate and top disc (D). Take measurements in at least three places, and use average as the actual clearance.

Clutch End-Plate-to-Top Disc Clearance
Service Limit: 
1st clutch: 1.23-1.43 mm (0.048-0.056 in.) 
2nd clutch: 0.75-0.95 mm (0.030-0.037 in.) 
3rd clutch: 0.83-1.03 mm (0.033-0.041 in.) 
4th clutch: 0.73-0.93 mm (0.029-0.037 in.) 
5th clutch: 0.73-0.93 mm (0.029-0.037 in.) 

14.If the clearance is out of the service limit, select a new clutch end-plate from the following table.

 

1ST and 3RD CLUTCH END-PLATES
Mark Part Number Thickness 
22551-PRP-003 2.3 mm (0.091 in.) 
22552-PRP-003 2.4 mm (0.094 in.) 
22553-PRP-003 2.5 mm (0.098 in.) 
22554-PRP-003 2.6 mm (0.102 in.) 
22555-PRP-003 2.7 mm (0.106 in.) 
22556-PRP-003 2.8 mm (0.110 in.) 
22557-PRP-003 2.9 mm (0.114 in.) 
22558-PRP-003 3.0 mm (0.118 in.) 
22559-PRP-003 3.1 mm (0.122 in.) 
10 22560-PRP-003 3.2 mm (0.126 in.) 
11 22561-PRP-003 3.3 mm (0.130 in.) 
12 22562-PRP-003 3.4 mm (0.134 in.) 

2ND CLUTCH END-PLATES
Mark Part Number Thickness 
22571-PRP-003 2.6 mm (0.102 in.) 
22572-PRP-003 2.7 mm (0.106 in.) 
22573-PRP-003 2.8 mm (0.110 in.) 
22574-PRP-003 2.9 mm (0.114 in.) 
22575-PRP-003 3.0 mm (0.118 in.) 
22576-PRP-003 3.1 mm (0.122 in.) 
22577-PRP-003 3.2 mm (0.126 in.) 
22578-PRP-003 3.3 mm (0.130 in.) 
22579-PRP-003 3.4 mm (0.134 in.) 

4TH and 5TH CLUTCH END-PLATES
Mark Part Number Thickness 
22581-RCL-003 2.1 mm (0.083 in.) 
22582-RCL-003 2.2 mm (0.087 in.) 
22583-RCL-003 2.3 mm (0.091 in.) 
22584-RCL-003 2.4 mm (0.094 in.) 
22585-RCL-003 2.5 mm (0.098 in.) 
22586-RCL-003 2.6 mm (0.102 in.) 
22587-RCL-003 2.7 mm (0.106 in.) 
22588-RCL-003 2.8 mm (0.110 in.) 
22589-RCL-003 2.9 mm (0.114 in.) 

15.Install the new clutch end-plate, then recheck the clearance.

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