End Clutch Installation using the Alto Kit

Auto Transmission DSMers: If you want to buy the Translab Shift Kit or Alto Kits: Try http://www.importperformancetransmissions.com He is a Transmission Specialist and has done a lot of work on DSM Transmissions. You will find him helping out on the DSM forums at www.dsmtalk.com. Look for the Automatic Transmission Forums.

For the Translab kits you can email Dean Mason of Translab. He is the creator of the kit and the owner of the company. deanmason@juno.com

Important! Please look at the End Clutch Seal replacement FAQ as well. It is recommended to do this at the same time. If you need the Alto Anti-Warp upgrade kit and Seals please click here

This is how I replaced the friction and steel plates/discs in the end clutch. Do at your own risk! Please refer to the instructions provided with the kit just in case I missed something. BTW, Hayne's has no mention of the end clutch at all. The transmission expert I spoke with recommends the end clutch and Shift Kit upgrade for the DSM autos to help prolong it's life and performance. Diagram of end clutch here.

	Jack up Car, remove passenger wheel and Plastic Shield protecting the side of the tranny. Drain transmission fluid using the drain plug on the pan (17mm). Note: You can get away with doing just a quart, but I always recommend changing the fluid as well. With 10mm socket remove the sensor plug (white arrow in pic) and the clutch cover (4 bolts).
	Here is the clutch cover on the ground. Check the bearing in there and see that it spins okay. Also, I put the gasket back into the groove going around the cover. The gasket was still on the tranny when I shot this pic.
	There is the clutch. It slides on and off a slotted spline.
	Before removing I like to mark the position by drawing a line to indicate where it was exactly on the spline. This is a habit of mine and not knowing whether it matters or not, I did to be safe. I used a CD marker in this case, it will write on a lot of surfaces and not rub off.
	The Clutch is removed. This is the gear underneath it. I also marked its position just it case it came off (see arrow). There is no need to remove this!
	The box the parts came in is my workbench for now. The center piece (arrow) is held there by a magnet, it will fall off. I left it there the whole time. Losing that may be bad.
	Alto recommends soaking the frictions in Transmission fluid before you install them. Your wife's (or significant other's) containers in the kitchen are great for this. Uhhh....no I haven't seen that lid dear. Also, the little screens in your bathroom sink's are great for straining debris from fluids and fit nicely into a funnel hole. Gee, every time I wash my hands they smell like Diamond ATF Fluid.
	Back to business. Remove the snap ring gently. Use a screwdriver to start it, then it should come out by hand.

	Start to disassemble. I used the top of the box to hold the old plates/discs and keep them in order. Note the pressure plate and snap ring on the top. Old friction disc in hand. Every plate/disc (8 total) will be replaced with the new plates/discs.
	Once they are all removed, start putting the new upgraded ones in. Starting with the Steel plate. Now is a good time to go to the End Clutch Seals page
	Then the new friction disc. From here on you alternate each one. Order is (starting from bottom) plate, disc, plate, disc, plate, disc, plate, disc, pressure plate and snap ring.
	Place the pressure plate back on.
	Here it is back together with snap ring in place. Now, line all of the teeth up as much as possible (see picture) so clutch slides onto the gear with no hassles. You can refer to your instructions for clearance requirements between the pressure plate and snap ring.
	When I placed the clutch on the spline and gear, I had to gently twist it side to side to get the teeth to slide back on. Forcing it on is not a good idea. I took it back off to align the teeth a couple of times before it went on. Here is the plug I removed in the first picture. Reassemble everything. I didn't have torque specs but I can tell you do not need to torque bolts too much. These little screws will strip real easy. Just ask your valve cover :). Refill the tranny fluid. I cleaned the outside of the tranny with degreaser so if it leaks I can tell. Drive and check for leaks.

Other Pics of Interest from a Spare Tranny I have::

Here is one of the old friction discs next to a new alto friction disc. Looks a little worn compared to the new ones. The one on the left had 66K.

	This is a transmission I picked up in my AWD purchase (F4A33 FWD). A spare that I am considering rebuilding. Here I remove the end clutch. Some rebuild pics here.
	Here is a friction disc with nothing left on it.
	The plates were popping out when I removed the snap ring due to extreme warpage. Here is one used OEM plate with 66K miles.
	Here is another. See why you need to change these to the anti-warp kit?

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