Service Manual2007 Captiva Forward (C1) and Direct Clutch (C2) Disassembly

Captiva

Forward (C1) and Direct Clutch (C2) Disassembly

Tools Required

J 28585 Snap Ring Remover

J 45186 Forward and Direct Clutch Spring Compressor

J 25024-A Servo Piston/Clutch Spring Compressor

J 23327 Clutch Spring Compressor

Remove the seal ring, thrust bearing and race.

Remove the seal ring from the input shaft assembly.

Remove the thrust bearing and race.

Remove the flange, disc and plate of forward clutch (C1).

Using J 28585, remove the snap ring.

Remove the 1 flange, 4 discs and 4 plates.

Remove the flange, disc, plate and cushion plate of direct clutch (C2).

Using 28585, remove the snap ring.

Remove the 1 flange, 4 discs, 4 plates and 1 cushion plate.

Remove the return spring assembly.

Place J 25024-A in a vise with the forcing screw on the bottom and backed out.
Place J 45186 over the shaft of the forward direct clutch housing and input shaft assembly.
Place J 21420-2 from J 23327 on the top of the forcing screw of J 24024-A.
With the forcing screw, compress the clutch spring to allow the removal of the snap ring.
Use J 28585 or snap ring pliers to remove the snap ring.
Remove the tools.

Remove the return spring assembly.

Caution : Wear safety glasses when using compressed air in order to prevent eye injury.

Remove the direct clutch(C2) piston.

Install the input shaft assembly on the rear case.

While pushing the piston by hand, apply compressed air (4kg/cm²) into the oil passage as shown in the figure and remove the C2 piston.

Important : Be careful not to damage the seal rings in the rear case.

Remove the O-ring from the C2 piston.

Caution : Wear safety glasses when using compressed air in order to prevent eye injury.

Remove the forward clutch (C1) piston.

While pushing the C1 piston by hand, apply compressed air (4kg/cm²) into the oil passage as shown in the figure and remove the C1 piston.

Remove the O-ring from the C1 piston.

Forward Clutch (C1) and Direct Clutch (C2) Inspection

Inspect the flange, disc and plate.

Check that the sliding surface of disc and plate is not worn or burnt. If the disc or plate is worn or burnt, replace it.

Important : Replace new clutch discs by soaking them at least 2 hours in ATF.

Inspect the forward clutch(C1) and direct clutch(C2) piston.

Check that the check ball is free by shaking the piston.
Check that the valve does not leak by applying compressed air.

Forward Clutch (C1) and Direct Clutch (C2) Assembly

Tools Required

J 28585 Snap Ring Remover

J 45186 Forward and Direct Clutch Spring Compressor

J 25024-A Servo Piston/Clutch Spring Compressor

J 23327 Clutch Spring Compressor

Install the forward clutch (C1) piston.

Coat the new O-rings with ATF and install them on the C1 piston.
Coat the inner surface of drum with ATF.
Press the C1 piston into the drum. Be careful not to damage the O-rings.

Install the direct clutch (C2).

Coat the new O-rings with ATF and install them on the piston.
Coat the inner surface of C1 piston with ATF.
Press the piston into the C1 piston.

Install the return spring assembly.

Place the return spring assembly on the direct clutch (C2) piston.

Important : Do not align the end gap of snap ring with the spring retainer claw.

Place J 25024-A in a vise with the forcing screw on the bottom and backed out.
Place J 45186 over the shaft of the forward direct clutch housing and input shaft assembly.
Place J 21420-2 from J 23327 on the top of the forcing screw of J 24024-A.
With the forcing screw, compress the clutch spring to allow the installation of the snap ring.
Use J 28585 or snap ring pliers to install the snap ring.
Remove the tools.

Install the flange, disc, plate and cushion plate of direct clutch (C2).

Install the cushion plate.

Important : Be sure the direction of cushion plate.

Install the flange, discs and plates as shown in the figure.

Important : Be sure number and order of flange and discs and plates.

Order : F-D-P-D-P-D-P-D-P-CP

Clutch/Brake	Flange (F)	Plate (P)	Disc (D)	Cushion Plate (CP)
Direct Clutch (C2)	1	4	4	1

Using J 28585, install the snap ring in the groove. Check that the end gap of snap ring is not aligned with one of the cutouts.

Install the flange,disc and plate of direct clutch (C1).

Install the flange, discs and plates as shown in the figure.

Important : Be sure number and order of flange and discs and plates.

Order : F-D-P-D-P-D-P-D-P

Clutch/Brake	Flange (F)	Plate (P)	Disc (D)
Forward Clutch (C1)	1	4	4

Using J 28585, install the snap ring in the groove. Check that the end gap of snap ring is not aligned with one of the cutouts.

Install the seal ring, thrust bearing and race.

Install the thrust bearing and race.

Coat the new seal ring with ATF, install it into the groove of the input shaft assembly.

Caution : Wear safety glasses when using compressed air in order to prevent eye injury.

Check the piston stroke of direct clutch (C2).

Install the input shaft assembly on the rear case and set a dial indicator as shown in the figure.
Apply the compressed air (4kg/cm²) and measure the C2 piston stroke.

Piston stroke : 1.49-1.91 mm (0.059-0.075 in.)

If the C2 piston stroke is out of standards,select another flange.

Flange thickness type : 4.0 mm (0.157 in.), 4.2 mm (0.165 in.), 4.4 mm (0.173 in.)

Caution : Wear safety glasses when using compressed air in order to prevent eye injury.

Check the piston stroke of forward clutch (C1).

Install the input shaft assembly on the rear case and set a dial indicator as shown in the figure.
Apply the compressed air (4kg/cm²) and measure the C1 piston stroke.

Piston stroke : 0.71-1.09 mm (0.028 - 0.043 in.)

If the C1 piston stroke is out of standards,select another flange.

Flange thickness type: 5.0 mm (0.197 in.), 5.2 mm (0.205 in.), 5.4 mm (0.213 in.)

Planetary Gear Assembly Inspection

Inspect the planetary gear bushing.

Using a dial indicator, measure the inner diameter of planetary gear bushing.

Important : Measure at different places and take an average. If it is greater than the maximum, replace it with a new planetary gear assembly.

Inner diameter:

Standard : 30.056-30.082 mm (1.183-1.184 in.)

Maximum: 30.132 mm (1.186 in.)

Inspect the planetary sun gear.

Using a dial indicator, measure the inner diameter of planetary sun gear bushing.

Important : Measure at different places and take an average. If it is greater than the maximum, replace it with a new planetary gear assembly.

Inner diameter:

Standard : 22.200-22.226 mm (0.874-0.875 in.)

Maximum: 22.276 mm (0.877 in.)

Front Planetary Ring Gear Disassembly

Remove the 1 way clutch No.2 (F2).

Remove the 1 way clutch No.2 (F2) from the front planetary ring gear.

Remove the snap ring with a screwdriver.
Remove the front planetary ring gear flange.

Front Planetary Ring Gear Assembly

Install the 1 way clutch No.2 (F2).

Install front planetary ring gear flange.
Install the snap ring.

Install the 1 way clutch No.2(F2) to the front planetary ring gear.

Operation Check Of 1 Way Clutch No.2 (F2)

Hold the front ring gear and check that the F2 inner race should turn freely counterclockwise and should lock clockwise.

Underdrive Clutch (C3) Disassembly

Tools Required

J 28585 Snap Ring Remover

J 23327 Clutch Spring Compressor

J 25024-A Servo Piston/Clutch Spring Compressor

J 45186 Forward and Direct Clutch Spring Compressor

Remove the underdrive clutch(C3) flange, disc and plate.

Remove the snap ring with a screwdriver.

Remove the 1 flange, 4 discs and 4 plates.

Important : Be careful not to damage the underdrive front planetary sun gear.

Remove the underdrive clutch(C3) return spring assembly.

Place J 25024-A in a vise with the forcing screw on the bottom and backed out.
Place J 45186 on the underdrive clutch(C3) return spring assembly.
Place J 21420-2 from J 23327 on top of the forcing screw of J 25024-A.
Place the clutch housing with the J 45186 on J 21420-2 and under the arms of J 25024-A.
With the forcing screw, compress the clutch spring to allow the removal of the snap ring.
Use J 28585 or snap ring pliers to remove the snap ring.
Remove the return spring assembly.

Caution : Wear safety glasses when using compressed air in order to prevent eye injury.

Remove the underdrive clutch(C3) piston.

Cover any 2 holes among 4 holes for oil passage of underdrive clutch (C3) with figures. Apply compressed air (4kg/cm²) to any 1 hole and remove the C3 piston.

Remove the O-rings from the C3 piston.

Underdrive Clutch (C3) Inspection

Inspect the flange, disc and plate.

Check that the sliding surface of disc and plate is not worn or burnt. If the disc or plate is worn or burnt, replace it.

Important : Replace new clutch discs by soaking them at least 2 hours in ATF.

Inspect the underdrive clutch (C3) piston.

Check that the check ball is free by shaking the piston.
Check that the valve does not leak by applying compressed air.

Inspect the underdrive clutch(C3) drum.

Using a dial indicator, measure the inner diameter of underdrive clutch(C3) drum bushing.

Important : Measure at different places and take an average. If it is greater than the maximum, replace it with a new one.

Inner diameter :

Standard : 36.125-36.150 mm (1.422-1.423 in )

Maximum: 36.200 mm (1.425 in.)

Underdrive Clutch (C3) Assembly

Tools Required

J 28585 Snap Ring Remover

J 23327 Clutch Spring Compressor

J 25024-A Servo Piston/Clutch Spring Compressor

J 45186 Forward and Direct Clutch Spring Compressor

Install the underdrive clutch (C3) piston.

Coat the new O-rings with ATF and install them on the piston.
Coat the inner surface of C3 drum with ATF.
Press the C3 piston into the C3 drum.

Important : Be careful not to damage the O-ring.

Install the underdrive clutch (C3) return spring assembly.

Place the underdrive clutch (C3) return spring assembly on the underdrive clutch (C3) piston.

Place J 25024-A in a vise with the forcing screw on the bottom and backed out.
Place J 45186 on the underdrive clutch(C3) return spring assembly.
Place J 21420-2 from J 23327 on top of the forcing screw of J 25024-A.
Place the clutch housing with the J 45186 on J 21420-2 and under the arms of J 25024-A.
With the forcing screw, compress the clutch spring to allow the installation of the snap ring.
Use J 28585 or snap ring pliers to install the snap ring.

Important : Be sure the end gap of snap ring is not aligned with the spring retainer claw.

Install the flange,disc and plate of underdrive clutch (C3).

Install the flange, plates and discs as shown in the figure.

Important : Be sure number and order of flange, plates and discs.

Order : F-D-P-D-P-D-P-D-P

Clutch/Brake	Flange (F)	Plate (P)	Disc (D)
Underdrive Clutch (C3)	1	4	4

Install the snap ring with a screwdriver in the groove. Check that the end gap of snap ring is not aligned with one of the cutouts.

Check the piston stroke of underdrive clutch (C3).

Pistion Stroke : 1.52-1.90 mm (0.059-0.075 in.)

If the C3 piston stroke is out of standards, select another flange.

Flange thickness type : 3.6 mm (0.142 in.), 3.8 mm (0.150 in.), 4.0 mm (0.157 in.)

Underdrive Brake (B4) Pistion Disassembly

Remove the underdrive brake (B4) piston.

Using a screwdriver, remove the E-ring.

Remove the B4 piston assembly as shown in the figure.

Inspect the spring.

Measure the free length and outer diameter of outer and inner springs.

Part name	Free length	Outer diameter
Outer spring	40.24 mm (1.584 in.)	20.3 mm (0.799 in.)
Inner spring	13.5 mm (0.531 in.)	10.0 mm (0.394 in.)

Underdrive Brake (B4) Pistion Assembly

Install the underdrive brake (B4) piston.

Install the B4 piston as shown in the figure.
Coat the new O-ring with ATF, install it into the groove of B4 piston.

Using the needle nose pliers, install the new E-ring into the groove of the B4 piston rod.

Valve Body Disassembly

Note : The valve body is only available as a complete unit for a service. The only components that can be independently serviced are the shift solenoids and the manual valve.