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.Assemble the 1st clutch of K20A4 and K20A5 engine models: Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (4) (C) and discs (4) (D), then install the clutch end plate (E) with the flat side toward the disc.

 

4.Assemble the 2nd clutch of K20A4 and K20A5 engine models: Install the waved spring (A) in the 2nd clutch drum (B). Install the clutch flat-plate (C), then starting with the clutch disc, alternately install the clutch discs (4) (D) and waved-plates (3) (E), then install the clutch end plate (F) with the flat side toward the disc.

 

5.Assemble the 3rd clutch of K20A4 and K20A5 engine models: Install the waved spring (A) in the 3rd clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (3) (C) and discs (3) (D), then install the clutch end plate (E) with the flat side toward the disc.

 

6.Assemble the 4th clutch of K20A4 and K20A5 engine models: Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (3) (C) and discs (3) (D), then install the clutch end plate (E) with the flat side toward the disc.

 

7.Assemble the 1st clutch of K24A1 engine model: Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch waved-pate, alternately install the clutch plates (5) (C) and discs (5) (D), then install the clutch end plate (E) with the flat side toward the disc.

 

8.Assemble the 2nd clutch of K24A1 engine model: Install the waved spring (A) in the 2nd clutch drum (B). Install the clutch flat-plate (C), clutch disc (D), and clutch flat-plate (E). Starting with the clutch disc, alternately install the clutch discs (4) (F) and clutch waved-pates (3) (G), then install the clutch end plate (H) with the flat side toward the disc.

 

9.Assemble the 3rd clutch of K24A1 engine model: Install the waved spring (A) in the 3rd clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (3) (C) and discs (3) (D), then install the clutch end plate (E) with the flat side toward the disc.

 

10.Assemble the 4th clutch of K24A1 engine model: Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (3) (C) and discs (3) (D), then install the clutch end plate (E) with the flat side toward the disc.

 

11.Install the snap ring with a screwdriver.

 

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

 

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

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

 

15.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). 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 the average as the actual clearance.

Clutch End Plate-to-Top Disc Clearance
Service Limit: 
K20A4 and K20A5 engine models 
 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: 0.73-0.93 mm (0.029-0.037 in.) 
 4th Clutch: 0.73-0.93 mm (0.029-0.037 in.) 
K24A1 engine model 
 1st Clutch: 1.28-1.48 mm (0.050-0.058 in.) 
 2nd Clutch: 0.85-1.05 mm (0.033-0.041 in.) 
 3rd Clutch: 0.73-0.93 mm (0.029-0.037 in.) 
 4th Clutch: 0.73-0.93 mm (0.029-0.037 in.) 

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

 

CLUTCH END PLATES
K20A4 and K20A5 Engine Models:
For 1st clutch
Plate No. 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.) 

For 2nd clutch
Plate No. 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.) 

For 3rd and 4th clutches
Plate No. Part Number Thickness 
11 22581-PRP-003 3.1 mm (0.122 in.) 
12 22582-PRP-003 3.2 mm (0.126 in.) 
13 22583-PRP-003 3.3 mm (0.130 in.) 
14 22584-PRP-003 3.4 mm (0.134 in.) 
15 22585-PRP-003 3.5 mm (0.138 in.) 
16 22586-PRP-003 3.6 mm (0.142 in.) 
17 22587-PRP-003 3.7 mm (0.146 in.) 
18 22588-PRP-003 3.8 mm (0.150 in.) 
19 22589-PRP-003 3.9 mm (0.154 in.) 

CLUTCH END PLATES
K24A1 Engine Model:
For 1st clutch
Plate No. Part Number Thickness 
22551-PPV-003 2.6 mm (0.102 in.) 
22552-PPV-003 2.7 mm (0.106 in.) 
22553-PPV-003 2.8 mm (0.110 in.) 
22554-PPV-003 2.9 mm (0.114 in.) 
22555-PPV-003 3.0 mm (0.118 in.) 
22556-PPV-003 3.1 mm (0.112 in.) 
22557-PPV-003 3.2 mm (0.126 in.) 
22558-PPV-003 3.3 mm (0.130 in.) 
22559-PPV-003 3.4 mm (0.134 in.) 

For 2nd clutch
Plate No. 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.) 

For 3rd and 4th clutches
Plate No. Part Number Thickness 
22571-PPV-A01 2.1 mm (0.083 in.) 
22572-PPV-A01 2.2 mm (0.087 in.) 
22573-PPV-A01 2.3 mm (0.091 in.) 
22574-PPV-A01 2.4 mm (0.094 in.) 
22575-PPV-A01 2.5 mm (0.098 in.) 
22576-PPV-A01 2.6 mm (0.102 in.) 
22577-PPV-A01 2.7 mm (0.106 in.) 
22578-PPV-A01 2.8 mm (0.110 in.) 
22579-PPV-A01 2.9 mm (0.114 in.) 

17.Install the new clutch end plate, then recheck the clearance.

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