A/T Clutch Clearance Inspection

Special Tools Required Clutch compressor attachment 07ZAE-PRP0100

1. Inspect the clutch piston, discs, plates, and end-plate for wear and damage, and inspect clutch wave-plate phase difference, if necessary.

1. Install the clutch piston in the clutch drum. Do not install the O-rings during inspection.

1. For K20Z2 engine model 1st clutch:
   Install the waved spring (A) in the clutch drum (B). Starting with the clutch wave-plate, alternately install the clutch wave-plates (C) (4), and discs (D) (4), and install the clutch end-plate (E) with the flat side toward the disc.

1. For K20Z2 engine model 2nd clutch:
   Install the waved spring (A) in the clutch drum (B). Install the clutch flat-plate (C), and clutch disc (D). Starting with the clutch wave-plate, alternately install the clutch wave-plates (E) (3), and discs (F) (3), and install the clutch end-plate (G) with the flat side toward the disc.

1. For K20Z2 engine model 3rd clutch:
   Install the waved spring (A) in the clutch drum (B). Install the clutch flat-plate (C), and clutch disc (D). Starting with the clutch wave-plate, alternately install the clutch wave-plates (E) (3), and discs (F) (3), and install the clutch end-plate (G) with the flat side toward the disc.

1. For K20Z2 engine model 4th clutch:
   Install the waved spring (A) in the clutch drum (B). Starting with the clutch wave-plate, alternately install the clutch wave-plates (C) (3), and discs (D) (3), and install the clutch end-plate (E) with the flat side toward the disc.

1. For K20Z2 engine model 5th clutch:
   Install the waved spring (A) in the clutch drum (B). Starting with the clutch wave-plate, alternately install the clutch wave-plates (C) (3), and discs (D) (3), and install the clutch end-plate (E) with the flat side toward the disc.

1. For K24A3 engine model 1st clutch:
   Install the waved spring (A) in the clutch drum (B). Starting with the clutch plate, alternately install the clutch plate (C) (5) and discs (D) (5), then install the clutch end-plate (E) with the flat side toward the disc.

1. For K24A3 engine model 2nd clutch:
   Install the waved spring (A) in the 2nd clutch drum (B). Install the clutch flat-plate (C), then starting with the clutch disc, alternately install the discs (D) (6) and clutch wave-plates (E) (5). Install the clutch end-plate (F) with the flat side toward the disc.

1. For K24A3 engine model 3rd clutch:
   Install the waved spring (A) in the clutch drum (B). Starting with the clutch plate, alternately install the clutch plate (C) (6) and discs (D) (6), then install the clutch end-plate (E) with the flat side toward the disc.

1. For K24A3 engine model 4th clutch:
   Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (4) and discs (D) (4). Install the clutch end-plate (E) with the flat side toward the disc.

1. For K24A3 engine model 5th clutch:
   Install the waved spring (A) in the 5th clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (4) and discs (D) (4). Install the clutch end-plate (E) with the flat side toward the disc.

1. Install the snap ring with a screwdriver.

1. Set a dial indicator (A) on the clutch end-plate (B).

1. Zero the dial indicator with the clutch end-plate lifted up to the snap ring (C).

1. Release the clutch end-plate to lower the clutch end-plate, then put the clutch compressor attachment on the end-plate (A).

1. Except for K24A3 engine model 1st and 3rd clutches: Press the clutch compressor attachment down with 150−160 N (15−16 kgf, 33−35 lbf) using a force gauge, and read the dial indicator (B).

1. For K24A3 engine model 1st and 3rd clutches:
   Press the clutch compressor attachment down with 39 N (4.0 kgf, 9 lbf) using a force gauge, and read the dial indicator (B).

1. The dial indicator reads the clearance (C) between the clutch end-plate and top disc (D). Take measurements in at least three places, and use average as the actual clearance.

   Clutch End-Plate-to-Top Disc Clearance
   K20Z2 Engine Model:
   Service Limit:
   1st Clutch: | 1.23−1.43 mm (0.048−0.056 in.)
   2nd Clutch: | 0.75−0.95 mm (0.030−0.037 in.)
   3rd Clutch: | 0.83−1.03 mm (0.033−0.041 in.)
   4th Clutch: | 0.73−0.93 mm (0.029−0.037 in.)
   5th Clutch: | 0.73−0.93 mm (0.029−0.037 in.)

   K24A3 Engine Model:
   Service Limit:
   1st Clutch: | 0.82−1.02 mm (0.032−0.040 in.)
   2nd Clutch: | 1.14−1.34 mm (0.045−0.053 in.)
   3rd Clutch: | 1.00−1.20 mm (0.039−0.047 in.)
   4th Clutch: | 0.93−1.10 mm (0.037−0.044 in.)
   5th Clutch: | 0.93−1.10 mm (0.037−0.044 in.)

1. If the clearance is out of the service limit, select a new clutch end-plate from the following table.

K20Z2 Engine Model 1ST and 3RD CLUTCH END-PLATES

Mark | Part Number | Thickness
--- | --- | ---
1 | 22551-PRP-003 | 2.3 mm (0.091 in.)
2 | 22552-PRP-003 | 2.4 mm (0.094 in.)
3 | 22553-PRP-003 | 2.5 mm (0.098 in.)
4 | 22554-PRP-003 | 2.6 mm (0.102 in.)
5 | 22555-PRP-003 | 2.7 mm (0.106 in.)
6 | 22556-PRP-003 | 2.8 mm (0.110 in.)
7 | 22557-PRP-003 | 2.9 mm (0.114 in.)
8 | 22558-PRP-003 | 3.0 mm (0.118 in.)
9 | 22559-PRP-003 | 3.1 mm (0.122 in.)
10 | 22560-PRP-003 | 3.2 mm (0.126 in.)
11 | 22561-PRP-003 | 3.3 mm (0.130 in.)
12 | 22562-PRP-003 | 3.4 mm (0.134 in.)

K20Z2 Engine Model 2ND CLUTCH END-PLATES

Mark | Part Number | Thickness
--- | --- | ---
1 | 22571-PRP-003 | 2.6 mm (0.102 in.)
2 | 22572-PRP-003 | 2.7 mm (0.106 in.)
3 | 22573-PRP-003 | 2.8 mm (0.110 in.)
4 | 22574-PRP-003 | 2.9 mm (0.114 in.)
5 | 22575-PRP-003 | 3.0 mm (0.118 in.)
6 | 22576-PRP-003 | 3.1 mm (0.122 in.)
7 | 22577-PRP-003 | 3.2 mm (0.126 in.)
8 | 22578-PRP-003 | 3.3 mm (0.130 in.)
9 | 22579-PRP-003 | 3.4 mm (0.134 in.)

K20Z2 Engine Model 4TH and 5TH CLUTCH END-PLATES

Mark | Part Number | Thickness
--- | --- | ---
1 | 22581-RCL-003 | 2.1 mm (0.083 in.)
2 | 22582-RCL-003 | 2.2 mm (0.087 in.)
3 | 22583-RCL-003 | 2.3 mm (0.091 in.)
4 | 22584-RCL-003 | 2.4 mm (0.094 in.)
5 | 22585-RCL-003 | 2.5 mm (0.098 in.)
6 | 22586-RCL-003 | 2.6 mm (0.102 in.)
7 | 22587-RCL-003 | 2.7 mm (0.106 in.)
8 | 22588-RCL-003 | 2.8 mm (0.110 in.)
9 | 22589-RCL-003 | 2.9 mm (0.114 in.)

K24A3 Engine Model 1ST CLUTCH END-PLATES

Mark | Part Number | Thickness
--- | --- | ---
F | 22551-RCT-A01 | 2.6 mm (0.102 in.)
G | 22552-RCT-A01 | 2.7 mm (0.106 in.)
H | 22553-RCT-A01 | 2.8 mm (0.110 in.)
J | 22554-RCT-A01 | 2.9 mm (0.114 in.)
K | 22555-RCT-A01 | 3.0 mm (0.118 in.)
L | 22556-RCT-A01 | 3.1 mm (0.122 in.)
M | 22557-RCT-A01 | 3.2 mm (0.126 in.)
N | 22558-RCT-A01 | 3.3 mm (0.130 in.)
P | 22559-RCT-A01 | 3.4 mm (0.134 in.)
Q | 22571-RCT-A01 | 2.6 mm (0.102 in.)
R | 22572-RCT-A01 | 2.7 mm (0.106 in.)
S | 22573-RCT-A01 | 2.8 mm (0.110 in.)
T | 22574-RCT-A01 | 2.9 mm (0.114 in.)
U | 22575-RCT-A01 | 3.0 mm (0.118 in.)
V | 22576-RCT-A01 | 3.1 mm (0.122 in.)
W | 22577-RCT-A01 | 3.2 mm (0.126 in.)
X | 22578-RCT-A01 | 3.3 mm (0.130 in.)
Y | 22579-RCT-A01 | 3.4 mm (0.134 in.)

K24A3 Engine Model 2ND CLUTCH END-PLATES

Mark | Part Number | Thickness
--- | --- | ---
10 | 22569-RCL-A01 | 2.4 mm (0.094 in.)
11 | 22570-RCL-A01 | 2.5 mm (0.098 in.)
1 | 22571-RCL-A01 | 2.6 mm (0.102 in.)
2 | 22572-RCL-A01 | 2.7 mm (0.106 in.)
3 | 22573-RCL-A01 | 2.8 mm (0.110 in.)
4 | 22574-RCL-A01 | 2.9 mm (0.114 in.)
5 | 22575-RCL-A01 | 3.0 mm (0.118 in.)
6 | 22576-RCL-A01 | 3.1 mm (0.122 in.)
7 | 22577-RCL-A01 | 3.2 mm (0.126 in.)

K24A3 Engine Model 3RD CLUTCH END-PLATES

Mark | Part Number | Thickness
--- | --- | ---
BA | 22551-RCT-A11 | 2.2 mm (0.087 in.)
BB | 22552-RCT-A11 | 2.3 mm (0.091 in.)
BC | 22553-RCT-A11 | 2.4 mm (0.094 in.)
BD | 22554-RCT-A11 | 2.5 mm (0.098 in.)
BE | 22555-RCT-A11 | 2.6 mm (0.102 in.)
BF | 22556-RCT-A11 | 2.7 mm (0.106 in.)
BG | 22557-RCT-A11 | 2.8 mm (0.110 in.)
BH | 22558-RCT-A11 | 2.9 mm (0.114 in.)
BJ | 22559-RCT-A11 | 3.0 mm (0.118 in.)
BK | 22571-RCT-A11 | 2.2 mm (0.087 in.)
BL | 22572-RCT-A11 | 2.3 mm (0.091 in.)
BM | 22573-RCT-A11 | 2.4 mm (0.094 in.)
BN | 22574-RCT-A11 | 2.5 mm (0.098 in.)
BP | 22575-RCT-A11 | 2.6 mm (0.102 in.)
BQ | 22576-RCT-A11 | 2.7 mm (0.106 in.)
BR | 22577-RCT-A11 | 2.8 mm (0.110 in.)
BS | 22578-RCT-A11 | 2.9 mm (0.114 in.)
BT | 22579-RCT-A11 | 3.0 mm (0.118 in.)

K24A3 Engine Model 4TH and 5TH CLUTCH END-PLATES

Mark | Part Number | Thickness
--- | --- | ---
1 | 22581-RCL-003 | 2.1 mm (0.083 in.)
2 | 22582-RCL-003 | 2.2 mm (0.087 in.)
3 | 22583-RCL-003 | 2.3 mm (0.091 in.)
4 | 22584-RCL-003 | 2.4 mm (0.094 in.)
5 | 22585-RCL-003 | 2.5 mm (0.098 in.)
6 | 22586-RCL-003 | 2.6 mm (0.102 in.)
7 | 22587-RCL-003 | 2.7 mm (0.106 in.)
8 | 22588-RCL-003 | 2.8 mm (0.110 in.)
9 | 22589-RCL-003 | 2.9 mm (0.114 in.)

1. Install the new clutch end-plate, then recheck the clearance.
   NOTE: If the thickest clutch end-plate is installed, but the clearance is still over the service limit, replace the clutch discs and plates.