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AUTOMATIC TRANSMISSION / TRANS − DIRECT CLUTCH ASSY (A245E/A246E)

DIRECT CLUTCH ASSY (A245E/A246E)

40028−01

OVERHAUL

1. INSPECT PISTON STROKE OF DIRECT CLUTCH

(a) Install the direct clutch on the oil pump.
SST (b) Set a dial indicator and measuring terminal (SST) togeth-
er, and measure the direct clutch piston stroke while ap-
plying and releasing compressed air (392 − 785 kPa, 4 −
8 kgf/cm2, 57 − 114 psi).
SST 09350−32014 (09351−32190)
Piston stroke:
Q02344 A245E: 0.935 − 1.335 mm (0.0368 − 0.0525 in.)
A246E: 1.12 − 1.52 mm (0.0441 − 0.0578 in.)
If the piston stroke is greater than the maximum, inspect each
component.

2. REMOVE DIRECT CLUTCH FLANGE HOLE SNAP

RING

(a) Using a screwdriver, remove the direct clutch flange hole

snap ring from the clutch drum.
3. REMOVE DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC

AT0163 (a) Remove the clutch flange, clutch discs and clutch plates
from the clutch drum.
4. REMOVE DIRECT CLUTCH RETURN SPRING
SST
SUB−ASSY

(a) Place SST on the spring retainer and compress the

springs with a press.
SST 09350−32014 (09351−32070)
(b) Remove the snap ring with the snap ring pliers.

AT2733

(c) Remove the direct clutch return spring sub−assy.

AT2734

A245E,A246E A/T REPAIR MANUAL (RM847E)

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AUTOMATIC TRANSMISSION / TRANS − DIRECT CLUTCH ASSY (A245E/A246E)

5. REMOVE DIRECT CLUTCH PISTON SUB−ASSY

(a) Install the direct clutch on the oil pump assy.

(b) Apply compressed air to the oil pump to remove the direct
clutch piston sub−assy (if the piston does not come out
completely, use needle−nose pliers to remove it).
(c) Remove the direct clutch from the oil pump assy.

AT0165

(d) Using a screwdriver, remove the 2 O−rings from the direct

clutch piston sub−assy.

AT2735

6. INSPECT DIRECT CLUTCH PISTON SUB−ASSY

(a) Check that the check ball is free by shaking the direct
clutch piston sub−assy.
(b) Check that the valve does not leak by applying low−pres-
sure compressed air.

AT0166 AT0167 D02424

7. INSPECT DIRECT MULTIPLE DISC CLUTCH CLUTCH

DISC

(a) Check if the sliding surfaces of the discs, plates and

Printed flanges are worn or burnt. If necessary, replace them.
Number HINT:
S If the lining of the disc is peeling off or discolored, or even
if a part of the printed number is defaced, replace all discs.
Q02605 S Before assembling new discs, soak them in ATF for at
least 15 minutes.
8. INSPECT DIRECT CLUTCH DRUM SUB−ASSY

(a) Using a dial indicator, measure the inside diameter of the

direct clutch drum sub−assy bushing.
Maximum inside diameter: 48.27 mm (1.9004 in.)
If the inside diameter is greater than the maximum, replace the
direct clutch drum sub−assy.

AT3231

A245E,A246E A/T REPAIR MANUAL (RM847E)

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AUTOMATIC TRANSMISSION / TRANS − DIRECT CLUTCH ASSY (A245E/A246E)

9. INSTALL DIRECT CLUTCH PISTON SUB−ASSY

(a) Install new O−rings to the direct clutch piston sub−assy.

Coat the O−rings with ATF.
(b) Being careful not to damage the O−rings, press the piston
into the drum with the cup side up.

AT0168

10. INSTALL DIRECT CLUTCH RETURN SPRING

SUB−ASSY

(a) Place the direct clutch return spring sub−assy and snap
ring onto the piston.

AT2734

(b) Place SST on the return spring, and compress the return
SST spring with a press.
SST 09350−32014 (09351−32070)
(c) Install the snap ring with snap ring pliers. Be sure the end
gap of the snap ring is not aligned with the spring retainer
claw.

AT2733

11. INSTALL DIRECT MULTIPLE DISC CLUTCH CLUTCH

Flange DISC

(a) Install the plates and discs in order.

Plate HINT:
Disc 245E: 2 plates and 2 discs
246E: 3 plates and 3 discs
Install in order: P = Plate D = Disc F = Flange
D02352 245E: P − D − P − D − F
246E: P − D − P − D − P − D − F
(b) Install the flange with the flat side facing downward.

A245E,A246E A/T REPAIR MANUAL (RM847E)

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AUTOMATIC TRANSMISSION / TRANS − DIRECT CLUTCH ASSY (A245E/A246E)

12. INSTALL DIRECT CLUTCH FLANGE HOLE SNAP

RING

(a) Using a screwdriver, install the direct clutch flange hole

snap ring.
(b) Check that the end gap of the direct clutch flange hole
snap ring is not aligned with one of the cutouts.

AT0163

13. INSTALL PISTON STROKE OF DIRECT CLUTCH

(a) Install the direct clutch onto the oil pump.
SST
(b) Set a dial indicator and measuring terminal (SST) togeth-
er, and measure the direct clutch piston stroke while ap-
plying and releasing compressed air (392 − 785 kPa, 4 −
8 kgf/cm2, 57 − 114 psi).
SST 09350−32014 (09351−32190)
Piston stroke:
Q02344 A245E: 0.935 − 1.335 mm (0.0368 − 0.0525 in.)
A246E: 1.12 − 1.52 mm (0.0441 − 0.0298 in.)
If the piston stroke is non−standard, select another flange.
HINT:
There are 4 different thickness for the flange.
Flange thickness: mm (in.)
thickness thickness
2.60 (0.1024) 3.00 (0.1181)
2.80 (0.1102) 3.20 (0.1260)

AT7710

A245E,A246E A/T REPAIR MANUAL (RM847E)