Clutch Drum And Input Shaft Assembly: Disassembly

WARNING: This page is about a different car, the 2006 Lexus IS 350. However, it is still accessible from the selected car via links, so may be relevant.

FIX CLUTCH DRUM AND INPUT SHAFT
1. Place the oil pump onto the torque converter clutch, and then place the reverse clutch drum subassembly and input shaft onto the oil pump.
  
  Fig 1: Placing Oil Pump Onto Torque Converter Clutch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE CLUTCH HUB SUB-ASSEMBLY
1. Using a screwdriver, remove the snap ring from the reverse clutch drum sub-assembly and input shaft.
  
  Fig 2: Removing/Installing Clutch Drum And Input Shaft Assembly Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the reverse clutch hub sub-assembly with the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 5 rear clutch discs, and the 4 clutch plates from the forward clutch hub.
  
  Fig 3: View Of Reverse Clutch Hub Sub-Assembly And Reverse Clutch Drum Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE CLUTCH REACTION SLEEVE
1. Remove the reverse clutch reaction sleeve from the reverse clutch hub sub-assembly.
  
  Fig 4: View Of Reverse Clutch Reaction Sleeve And Reverse Clutch Hub Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 3 CLUTCH DISC
1. Remove the clutch cushion plate, the reverse clutch flange, the 4 plates and the 5 discs from the reverse clutch hub.
INSPECT NO. 3 CLUTCH DISC (See INSPECTION )

Fig 5: Identifying No. 3 Clutch Disc
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY (See REASSEMBLY )
REMOVE CLUTCH HUB SUB-ASSEMBLY
1. Remove the clutch hub sub-assembly and thrust washer from the reverse clutch drum sub-assembly.
  
  Fig 6: View Of Clutch Hub Thrust Washer, Forward Clutch Hub Sub-Assembly And Clutch Drum Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 thrust needle roller bearings from the clutch hub sub-assembly.
INSPECT CLUTCH HUB SUB-ASSEMBLY (See INSPECTION )

Fig 7: Identifying Thrust Needle Roller Bearings And No. 3 Thrust Bearing Race
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COAST CLUTCH HUB SUB-ASSEMBLY
1. Remove the coast clutch hub sub-assembly from the reverse clutch drum sub-assembly.
INSPECT UNDERDRIVE ONE WAY CLUTCH ASSEMBLY (See INSPECTION )

Fig 8: Identifying Coast Clutch Hub Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE UNDERDRIVE ONE WAY CLUTCH ASSEMBLY
1. Remove the underdrive one way clutch assembly, clutch hub thrust washer and the thrust bearing race from the coast clutch hub.
  
  Fig 9: Identifying Underdrive 1 Way Clutch Assembly, Clutch Hub Thrust Washer And Thrust Bearing Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CLUTCH DISC
1. Using a screwdriver, remove the hole snap ring.
  
  Fig 10: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the flange, cushion plate, 4 discs and 4 plates from the input shaft.
INSPECT NO. 1 CLUTCH DISC (See INSPECTION )

Fig 11: Identifying Flange, Cushion Plate, 4 Discs And 4 Plates
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COAST CLUTCH DISC
1. Using a screwdriver, remove the hole snap ring.
  
  Fig 12: Identifying Hole Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the flange, the 3 discs and the 3 plates from the input shaft.
INSPECT COAST CLUTCH DISC (See INSPECTION )

Fig 13: Removing Flange, Discs And Plates From Input Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT
1. Remove the thrust needle roller bearing from the input shaft.
  
  Fig 14: Identifying Thrust Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the input shaft from the reverse clutch drum sub-assembly.
  
  Fig 15: View Of Input Shaft Assembly And Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the thrust needle roller bearing and thrust bearing race from the reverse clutch drum subassembly.
  
  Fig 16: Identifying Thrust Needle Roller Bearing And Thrust Bearing Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT OIL SEAL RING
1. Remove the 4 oil seal rings from the input shaft.
  
  Fig 17: Identifying 4 Oil Seal Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CLUTCH BALANCER
1. Place SST on the No. 1 clutch balancer, and compress the return spring with a press.
  SST 09350-30020 (09350-07040)
2. Using the SST, remove the snap ring.
  SST 09350-30020 (09350-07070)
  
  Fig 18: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the No. 1 clutch balancer and the forward clutch return spring from the input shaft.
  
  Fig 19: Identifying No. 1 Clutch Balancer And Forward Clutch Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the D-ring from the No. 1 clutch balancer.
INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY (See INSPECTION )

Fig 20: Identifying D-Ring For No. 1 Clutch Balancer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FORWARD CLUTCH PISTON SUBASSEMBLY
1. Holding the forward clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm² , 57 psi) to the input shaft to remove the forward clutch piston.
  
  Fig 21: Identifying Forward Clutch Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the coast clutch piston from the forward clutch piston.
3. Remove the O-ring from the input shaft.
  
  Fig 22: Identifying Coast Clutch Piston & Forward Clutch Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE CLUTCH FLANGE
1. Remove the reverse clutch flange from the reverse clutch drum sub-assembly.
  
  Fig 23: Removing/Installing Reverse Clutch Flange
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 DIRECT CLUTCH DISC
1. Using a screwdriver, remove the 2 hole snap rings from the reverse clutch drum sub-assembly.
  
  Fig 24: Removing/Installing Clutch Drum Hole Snap Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the direct clutch flange, the 6 plates and the 5 discs from the reverse clutch drum subassembly.
INSPECT NO. 2 DIRECT CLUTCH DISC (See INSPECTION )

Fig 25: Identifying Direct Clutch Flange, Plates And Discs
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 3 CLUTCH BALANCER
1. Place SST on the No. 3 clutch balancer, and compress the return spring with a press.
  SST 09387-00070
2. Using SST, remove the snap ring.
  SST 09350-30020 (09350-07070)
3. Remove the No. 3 clutch balancer.
  
  Fig 26: Removing/Installing Clutch Balancer No. 3 Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE CLUTCH RETURN SPRING SUBASSEMBLY
1. Remove the reverse clutch return spring and the Oring from the reverse clutch piston.
INSPECT REVERSE CLUTCH RETURN SPRING SUBASSEMBLY (See INSPECTION )

Fig 27: Identifying O-Ring On Reverse Clutch Piston Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE CLUTCH PISTON SUBASSEMBLY
1. Remove the reverse clutch piston sub-assembly from the reverse clutch drum sub-assembly.
  
  Fig 28: Identifying Reverse Clutch Drum Sub-Assembly & Reverse Clutch Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the O-ring from the reverse clutch piston sub-assembly.
  
  Fig 29: Identifying Reverse Clutch Piston Sub-Assembly O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the O-ring from the reverse clutch drum sub-assembly.
  
  Fig 30: Identifying Clutch Drum O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIRECT CLUTCH PISTON SUB-ASSEMBLY
1. Place SST on the direct clutch piston, and compress the return spring with a press.
  SST 09320-89010
2. Using SST, remove the snap ring.
  SST 09350-30020 (09350-07070)
  
  Fig 31: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using 2 screwdrivers, remove the direct clutch piston sub-assembly from the reverse clutch drum sub-assembly.
  
  Fig 32: Identifying Direct Clutch Piston Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the No. 2 clutch balancer and the direct clutch return spring sub-assembly from the direct clutch piston sub-assembly.
  
  Fig 33: View Of Clutch Balancer Return Spring Sub Assembly And Direct Clutch Piston Sub Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the 2 O-rings from the direct clutch piston sub-assembly.
INSPECT DIRECT CLUTCH RETURN SPRING SUBASSEMBLY (See INSPECTION )

Fig 34: Identifying Direct Clutch Piston O-Rings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002