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Direct Clutch: Reassembly

  1. Install the O-rings on direct clutch retainer and piston.
  2. Install the clutch piston.
  3. Install the O-ring on spring retainer and install return spring and retainer.
  4. Install the snap ring using the special tool(09453 - 21000).
    Fig 1: Installing Snap Ring Using Special Tool
    G03877270Courtesy of KIA MOTORS AMERICA, INC.
  5. Aligning the teeth of the clutch plate, the clutch disc, and the clutch reaction plate (fig.A) and the direct clutch retainer hole (fig.B), assemble them.
    Fig 2: Aligning Teeth Of Clutch Plate
    G03877271Courtesy of KIA MOTORS AMERICA, INC.
  6. Install the direct clutch reaction plate as illustrated on the figure.
  7. Applying force of 5kg on the direct clutch reaction plate, measure the gap with the snap ring using a gauge. If the measurement deviates from standard value, use an appropriate snapring (12 sizes).

    Standard value

    F5A51-2: 0.024 - 0.031 in(0.6 - 0.8mm)

    Fig 3: Installing Direct Clutch Reaction Plate
    G03877272Courtesy of KIA MOTORS AMERICA, INC.