Direct Clutch Assembly (C-2): Reassembly

Coat new O-rings with ATF and install them on the direct clutch piston.
Install direct clutch piston to direct clutch drum.
Being careful not to damage the O-rings, press in the direct clutch piston into the clutch drum, using both hands.

Fig 1: Pressing Direct Clutch Piston Into Clutch Drum
Courtesy of ISUZU MOTOR CO.
Install piston return spring.

Fig 2: Installing Piston Return Spring
Courtesy of ISUZU MOTOR CO.
Compress piston return spring and install snap ring in groove.
- Place special tool on the spring retainer, and compress the return spring.
- 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.
Spring compressor: J-25048

Fig 3: Compressing Piston Return Spring & Installing Snap Ring
Courtesy of ISUZU MOTOR CO.
Install four plates and four discs.
Install in order: P-D-P-D-P-D-P-D

P: Plate

D: Disc

Fig 4: Installing Four Plates & Four Discs
Courtesy of ISUZU MOTOR CO.
Install the flange, with the flat side facing downward.

Fig 5: Installing Flange With Flat Side Facing Downward
Courtesy of ISUZU MOTOR CO.
Install the snap ring with a screwdriver.
Be sure the end gap of the snap ring is not aligned with the cutout portion of the direct clutch drum.

Fig 6: Installing Snap Ring With Screwdriver
Courtesy of ISUZU MOTOR CO.

Check piston stroke of direct clutch (C-2).

Place the direct clutch assembly onto the OD support assembly.

Fig 7: Placing Direct Clutch Assembly Onto OD Support Assembly

Courtesy of ISUZU MOTOR CO.

Using a dial indicator, measure the direct clutch piston stroke by applying and releasing compressed air (390 - 780 kPa or 57 - 114 psi) as shown in Fig 8.

Pack clearance: 0.4 - 0.7 mm (0.016 - 0.028 in)

If the piston stroke is not within specification, replace the discs and recheck the piston stroke.

If the piston stroke is nonstandard, select another flange.

FLANGE SIZES

Flange thickness	Flange thickness
3.3 mm (0.130 in)	3.8 mm (0.150 in)
3.4 mm (0.134 in)	-
3.5 mm (0.138 in)	4.0 mm (0.157 in)
3.6 mm (0.142 in)	-
3.7 mm (0.146 in)	4.2 mm (0.165 in)

Fig 8: Measure Direct Clutch Piston Stroke With Dial Indicator

Courtesy of ISUZU MOTOR CO.

Coat the clutch drum thrust washer (plastic) with petroleum jelly and install it onto the direct clutch.
NOTE: Make sure that the lugs fit into the cutout portions on the direct clutch.

Fig 9: Installing Clutch Drum Thrust Washer (Plastic) Onto Direct Clutch
Courtesy of ISUZU MOTOR CO.

Align the flukes of discs in the direct clutch.

Install the direct clutch assembly onto the forward clutch assembly.

Check that the distance from the direct clutch end to the forward clutch end is 71.2 mm (2.803 in).

Fig 10: Checking Distance From Direct Clutch End To Forward Clutch End
Courtesy of ISUZU MOTOR CO.