Forward/Coast/Direct Clutches: Disassembly

Fig 1: Exploded View Of Forward/Coast/Direct Clutches

Courtesy of MAZDA MOTORS CORP.

Fig 2: Removing Direct Clutch Pressure Plate Retaining Ring

Courtesy of MAZDA MOTORS CORP.

1. Remove the direct clutch pressure plate retaining ring.
   Fig 3: Removing Direct Clutch Pack

   Courtesy of MAZDA MOTORS CORP.
2. Disassemble the direct clutch pack.
   1. Remove the direct clutch pressure plate.
   2. Remove the direct clutch steel plates.
   3. Remove the direct clutch friction plates.
      Fig 4: Compressing Direct Clutch Return Springs Using Special Tool

      Courtesy of MAZDA MOTORS CORP.
      WARNING:

      • Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions may result in personal injury.
      CAUTION:

      • Do not compress the direct clutch return springs completely.
3. Remove the direct clutch spring retaining ring.
   1. Using the special tool, compress the direct clutch return springs.
   2. Remove the direct clutch return spring retaining ring.
      Fig 5: Removing Direct Clutch Return Spring Assembly

      Courtesy of MAZDA MOTORS CORP.
4. Remove the direct clutch return spring assembly.
   Fig 6: Removing Direct Clutch Piston Assembly

   Courtesy of MAZDA MOTORS CORP.
5. Remove the direct clutch piston assembly.
   Fig 7: Removing Direct Clutch Piston Outer Lip Seal

   Courtesy of MAZDA MOTORS CORP.
6. Remove and discard the direct clutch piston outer lip seal.
   Fig 8: Removing Direct Clutch Piston Inner Lip Seal

   Courtesy of MAZDA MOTORS CORP.
7. Remove and discard the direct clutch piston inner lip seal from the forward/coast/direct clutch cylinder assembly.
   Fig 9: Removing Forward Clutch Pressure Plate Retaining Ring

   Courtesy of MAZDA MOTORS CORP.
8. Remove the forward clutch pressure plate retaining ring.
   Fig 10: Removing Forward And Coast Clutch Plates

   Courtesy of MAZDA MOTORS CORP.
9. Remove the forward and coast clutch plates.
   1. forward clutch pressure plate
   2. forward clutch external spline clutch plates (steel)
   3. coast clutch internal spline clutch plates (friction)
   4. coast clutch external spline clutch plates (steel)
   5. coast clutch pressure plate
   6. forward clutch wave spring
   7. forward clutch internal spline clutch plates (friction)
      Fig 11: Compressing Return Spring Using Special Tool

      Courtesy of MAZDA MOTORS CORP.
      WARNING:

      • Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions can result in personal injury.
      CAUTION:

      • Do not compress the return springs completely.
10. Remove the forward/coast clutch return spring retaining ring.
    1. Using the special tool, compress the return spring.
    2. Remove the retaining ring.
       Fig 12: Removing Forward/Coast Clutch Return Spring Assembly

       Courtesy of MAZDA MOTORS CORP.
11. Remove the forward/coast clutch return spring assembly.
    Fig 13: Removing Forward And Coast Clutch Pistons

    Courtesy of MAZDA MOTORS CORP.
12. Remove the forward and coast clutch pistons.
    Fig 14: Removing Forward Clutch Piston Inner Seal Using Special Tool

    Courtesy of MAZDA MOTORS CORP.
13. Using the special tool, remove and discard the forward clutch piston inner seal from the forward/coast/direct clutch cylinder assembly.
    Fig 15: Removing Forward Clutch Piston Outer Lip Seal

    Courtesy of MAZDA MOTORS CORP.
14. Remove and discard the forward clutch piston outer lip seal.
    Fig 16: Separating Coast Clutch Piston Assembly

    Courtesy of MAZDA MOTORS CORP.
15. Separate the coast clutch piston assembly from the forward clutch piston assembly.
    WARNING:

    • Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Failure to follow these instructions can result in personal injury.
    NOTE:

    • Do not clean the clutch plates in a vapor degreaser or in any other type of detergent solution.
16. Clean all parts thoroughly in a clean solvent and blow dry with moisture-free regulated compressed air.
    • Clean the steel clutch plates with a lint-free cloth.
    • Soak the new clutch plates in the specified transaxle fluid before assembly.
17. Inspect the parts for damage, cracks or wear.
    • spline teeth
    • clutch plates
    • seals
    • bushing
    • check balls in pistons
    • piston bore
    • passages and lubrication holes in the forward/coast/direct clutch cylinder
    • center hub weld
    • large snap ring grooves