Automatic Transmission: Clutch: Reassembly

NOTE:

Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air.
Blow out all passages.
Lubricate all parts with ATF before reassembly.

Inspect the check valve; if it's loose, replace the piston.

Fig 1: Identifying Check Valve And Piston
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Install new O-rings on the clutch piston.

Fig 2: Installing O-Rings On Clutch Piston
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Install the piston in the clutch drum. Apply pressure and rotate to ensure proper seating.
NOTE: Lubricate the piston O-ring with ATF before installing.

CAUTION: Do not pinch the O-ring by installing the piston with too much force.

Fig 3: Installing Piston In Clutch Drum
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the return spring and spring retainer, and position the snap ring on the retainer.

Fig 4: Identifying Return Spring, Spring Retainer And Snap Ring
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Install the special tools as shown.

Fig 5: Identifying Special Tools
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CAUTION: If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged. Be sure the special tool is adjusted to have full contact with the spring retainer.

Fig 6: Identifying Special Tool Position
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Compress the return spring.

Fig 7: Compressing Return Spring
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Install the snap ring.

Fig 8: Installing Snap Ring
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Remove the special tools.
Install the disc spring.
NOTE: Install the disc spring in the direction shown, except 2nd clutch.

Fig 9: Identifying Disc Spring And Clutch Drum
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Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.
Starting with a clutch plate, alternately install the clutch plates and discs. Install the clutch end plate with flat side toward the disc.
NOTE: Before installing the plates and discs, make sure the inside of the clutch drum is free of dirt or other foreign matter.

Fig 10: Installing Plates And Discs
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Install the snap ring.

Fig 11: Installing Snap Ring
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Measure the clearance between the clutch end plate and top disc with a dial indicator. Zero the dial indicator with the clutch end plate lowered and lift it up to the snap ring. The distance that the clutch end plate moves is the clearance between the clutch end plate and top disc.

NOTE: Take measurements in at least three places, and use the average as the actual clearance.

Clutch End Plate-to-Top Disc Clearance:

CLUTCH END PLATE SPECIFICATION

Clutch	Service Limit
1st	0.65 - 0.85 mm (0.026 - 0.033 in)
2nd	0.65 - 0.85 mm (0.026 - 0.033 in)
3rd	0.40 - 0.60 mm (0.016 - 0.024 in)
4th	0.40 - 0.60 mm (0.016 - 0.024 in)

Fig 12: Measuring Clearance Between Clutch End Plate And Top Disc

Courtesy of AMERICAN HONDA MOTOR CO., INC.

If the clearance is not within the service limits, select a new clutch end plate from the following table.

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

Fig 13: Identifying Clutch End Plate Thickness

Courtesy of AMERICAN HONDA MOTOR CO., INC.

CLUTCH END PLATE

CLUTCH END PLATE SPECIFICATION

Plate No.	Part Number	Thickness
1	22551 - P4R - 003	2.1 mm (0.083 in)
2	22552 - P4R - 003	2.2 mm (0.087 in)
3	22553 - P4R - 003	2.3 mm (0.091 in)
4	22554 - P4R - 003	2.4 mm (0.094 in)
5	22555 - P4R - 003	2.5 mm (0.098 in)
6	22556 - P4R - 003	2.6 mm (0.102 in)
7	22557 - P4R - 003	2.7 mm (0.106 in)
8	22558 - P4R - 003	2.8 mm (0.110 in)
9	22559 - P4R - 003	2.9 mm (0.114 in)