For 1990-2009 cars

#### Tools Required

• | DT 46451 (DW240-020) Brake/Clutch Spring Compressor

• | DT 46452 (DW240-030) Forward Clutch Adapter

• | DT 46520 (DW240-120) Measuring Terminal

1. Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover.
2. Using a dial indicator, measure the reverse clutch pack clearance while applying and releasing 392 kPa (57 psi) of compressed air.

If the stroke is non-standard, inspect the discs, plates, and flange.

Specifications
The pack clearance is 0.4-1 mm (0.0157-0.0394 in).

3. Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover.
4. Using a dial indicator and the DT 46520 (1) , measure the forward clutch pack clearance while applying and releasing 392 kPa (57 psi) of compressed air.

• | The forward and reverse clutch will come out as you apply the compressed air. Therefore, while the checking is being done, press on the input shaft of the forward and reverse clutch using stamping machine or alike so that the pressure is not applied on the forward and reverse clutch.

• | If the stroke is non-standard, inspect the discs, plates and flange.

Specifications
The pack clearance is 1.1-1.5 mm (0.043-0.059 in).

5. Using a screwdriver, remove the reverse clutch snap ring.
6. Remove the 2 flanges (1), the 2 discs (3), and the plate (2) from the reverse clutch drum.
7. Using a screwdriver, remove the snap ring.
8. Remove the flange (1), 3 discs (3), and 3 plates (2) from the forward clutch drum.
9. Using the DT 46451 (1) and the DT 46452 (2) , compress the spring.

Important: Do not expand the snap ring excessively.

10. Using a snap ring expander, remove the snap ring.
11. Remove the clutch balancer and forward clutch return spring.
12. Install the forward and reverse multiple disc clutch on the transaxle rear cover.

Important:

• | Air pressure may cause the pistons to jump-out. When removing the piston, hold it with your hand using a waste cloth.

• | Take care not to splash automatic transmission fluid (ATF) when air-blowing.

13. Apply 392 kPa (57 psi) of compressed air to the transaxle rear cover to remove the forward clutch piston.

When the piston cannot be removed as it is slanted, either blow the air again with the protruding side pushed or remove the piston using a needle-nose pliers with vinyl tape on the tip.

Important: Air pressure may cause the drums to jump-out. When removing the drum, hold it with your hand using a waste cloth.

14. Apply 392 kPa (57 psi) of compressed air to the transaxle rear cover to remove the forward clutch drum.

When the drum can not be removed as it is slanted, either blow the air again with the protruding side pushed or remove the drum using a needle nose pliers with vinyl tape on the tip.

15. Using a small screwdriver, remove the O-ring (1) from the forward clutch drum.
16. Using a small screwdriver, remove the O-ring (1) from the intermediate shaft sub-assembly.