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Clutch Drum And Input Shaft Assembly: Inspection

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.
  1. INSPECT UNDERDRIVE ONE WAY CLUTCH ASSEMBLY 
    1. Hold the coast clutch hub and turn the one way clutch assembly.
    2. Check that the one way clutch assembly turns freely counterclockwise and locks clockwise.
      Fig 1: Checking One Way Clutch Assembly
      G04053402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If there is a problem with the one way clutch, replace it.

  2. INSPECT DIRECT CLUTCH RETURN SPRING SUBASSEMBLY 
    1. Using vernier calipers, measure the free length of the spring together with the spring seat.

      Standard free length: 19.51 mm (0.768 in.) 

      Fig 2: Measuring Free Length Of Spring Together With Spring Seat
      G04053403Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the free length is shorter than the standard free length, replace the clutch return spring subassembly.

  3. INSPECT REVERSE CLUTCH RETURN SPRING SUBASSEMBLY 
    1. Using vernier calipers, measure the free length of the spring together with the spring seat.

      Standard free length: 21.04 mm (0.828 in.) 

      Fig 3: Measuring Free Length Of Spring Together With Spring Seat
      G04053403Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the free length is shorter than the standard free length, replace the clutch return spring subassembly.

  4. INSPECT NO. 2 DIRECT CLUTCH DISC 
    1. Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt.

      If necessary, replace them.

      Fig 4: Inspecting Disc
      G04019470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the linings of the discs are peeled off or discolored, or even a part of the printed numbers is damaged, replace all discs.
      • Before assembling new discs, soak them in ATF for at least 15 minutes.
  5. INSPECT PACK CLEARANCE OF NO. 2 DIRECT CLUTCH 
    1. Inspect the pack clearance of the No. 2 direct clutch.
      1. Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across a diameter while blowing air into the oil hole as shown in the illustration, and calculate the average.
        Fig 5: Inspecting Pack Clearance Of No. 2 Direct Clutch
        G04053406Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT:

        Flange moving distance A = 0.36 to 1.24 mm (0.0142 to 0.0488 in.)

        Pack clearance = Flange moving distance A - 0.05 mm (0.002 in.)

        Pack Clearance: 0.5 to 0.8 mm (0.020 to 0.031 in.) 

        NOTE: Install a selective flange {t = 3.4 mm (0.1339 in.)} when measuring the moving distance (shaded area in the illustration).
      2. If the pack clearance is outside the specified range, select and install a clutch flange that brings the pack clearance within the specified range.

        HINT:

        There are 9 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

        Flange thickness 

        FLANGE THICKNESS

        No. Thickness
        2 3.0 mm (0.118 in.)
        3 3.1 mm (0.122 in.)
        4 3.2 mm (0.126 in.)
        5 3.3 mm (0.130 in.)
        6 3.4 mm (0.134 in.)
        7 3.5 mm (0.138 in.)
        8 3.6 mm (0.142 in.)
        9 3.7 mm (0.146 in.)
        A 3.8 mm (0.150 in.)
  6. INSPECT PACK CLEARANCE OF NO. 3 CLUTCH 
    1. Inspect the pack clearance of the reverse clutch hub sub-assembly.
      1. Using a dial indicator, measure the reverse clutch piston stroke (distance A) and the moving distance (distance B) of the reverse clutch flange at both ends across a diameter while blowing air (392 kPa, 4 kgf/cm2 , 57 psi) from the oil hole as shown in the illustration, and calculate the average.
        Fig 6: Inspecting Pack Clearance Of No. 3 Clutch
        G04053407Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT:

        Piston stroke A = 1.05 to 2.15 mm (0.0413 to 0.0846 in.)

        Flange moving distance B = 0.72 to 1.08 mm (0.0283 to 0.0425 in.)

        Pack clearance = Piston stroke A - Flange moving distance B - 0.06mm (0.0024 in.)

        Pack Clearance: 0.5 to 0.8 mm (0.020 to 0.031 in.) 

        NOTE: Install a selective flange {t = 3.3 mm (0.1299 in.)} when measuring the moving distance (shaded area in the illustration).
      2. If the pack clearance is outside the specified range, select and install a clutch flange that brings the pack clearance within the specified range.

        HINT:

        There are 11 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

        Flange thickness 

        FLANGE THICKNESS

        No. Thickness
        0 2.8 mm (0.110 in.)
        1 2.9 mm (0.114 in.)
        2 3.0 mm (0.118 in.)
        3 3.1 mm (0.122 in.)
        4 3.2 mm (0.126 in.)
        5 3.3 mm (0.130 in.)
        6 3.4 mm (0.134 in.)
        7 3.5 mm (0.138 in.)
        8 3.6 mm (0.142 in.)
        9 3.7 mm (0.146 in.)
        A 3.8 mm (0.150 in.)
  7. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Using vernier calipers, measure the free length of the spring together with the spring seat.

      Standard free length: 24.64 mm (0.9701 in.) 

      If the free length is shorter than the standard free length, replace the clutch return spring subassembly.

      Fig 7: Measuring Free Length Of Spring Together With Spring Seat
      G04053403Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSPECT COAST CLUTCH DISC 
    1. Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt.

      If necessary, replace them.

      Fig 8: Inspecting Disc
      G04019470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the linings of the discs are peeled off or discolored, or even a part of the printed numbers is damaged, replace all discs.
      • Before assembling new discs, soak them in ATF for at least 15 minutes.
  9. INSPECT PACK CLEARANCE OF COAST CLUTCH 
    1. Inspect the pack clearance of the coast clutch hub sub-assembly.
      1. Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.

        HINT:

        Flange moving distance A = 0.38 to 1.48 mm (0.01496 to 0.0583 in.)

        Pack clearance = Flange moving distance A - 0.02 mm (0.0008 in.)

        Fig 9: Inspecting Pack Clearance Of Coast Clutch
        G04053410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Pack Clearance: 0.3 to 0.6 mm (0.012 to 0.024 in.) 

        NOTE: Install a selective flange {t = 3.0 mm (0.118 in.)} when measuring the moving distance (shaded area in the illustration).
      2. If the pack clearance is outside the specified range, select and install a clutch flange that brings the pack clearance within the specified range.

        HINT:

        There are 10 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

        Flange thickness 

        FLANGE THICKNESS

        No. Thickness
        0 3.0 mm (0.118 in.)
        1 3.1 mm (0.122 in.)
        2 3.2 mm (0.126 in.)
        3 3.3 mm (0.130 in.)
        4 3.4 mm (0.134 in.)
        5 3.5 mm (0.138 in.)
        6 3.6 mm (0.142 in.)
        7 3.7 mm (0.146 in.)
        8 3.8 mm (0.150 in.)
        9 3.9 mm (0.154 in.)
  10. INSPECT NO. 1 CLUTCH DISC 
    1. Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt. If necessary, replace them.
      Fig 10: Inspecting Disc
      G04019470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the linings of the discs are peeled off or discolored, or even a part of the printed numbers is damaged, replace all discs.
      • Before assembling new discs, soak them in ATF for at least 15 minutes.
  11. INSPECT PACK CLEARANCE OF NO. 1 CLUTCH 
    1. Inspect the pack clearance of the No. 1 clutch.
      1. Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.

        HINT:

        Flange moving distance A = 0.36 to 1.50 mm (0.0142 to 0.0591 in.)

        Fig 11: Inspecting Pack Clearance Of No. 1 Clutch
        G04053412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Pack clearance = Flange moving distance A - 0.11 mm (0.0043 in.)

        Pack Clearance: 0.56 to 0.86 mm (0.0220 to 0.0339 in.) 

        NOTE: Install a selective flange t = 3.4 mm (0.134 in.) when measuring the moving distance (shaded area in the illustration).
      2. If the pack clearance is outside the specified range, select and install a clutch flange that brings the pack clearance within the specified range.

        HINT:

        There are 11 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

        Flange thickness 

        FLANGE THICKNESS

        No. Thickness
        0 3.0 mm (0.118 in.)
        1 3.1 mm (0.122 in.)
        2 3.2 mm (0.126 in.)
        3 3.3 mm (0.130 in.)
        4 3.4 mm (0.134 in.)
        5 3.5 mm (0.138 in.)
        6 3.6 mm (0.142 in.)
        7 3.7 mm (0.146 in.)
        8 3.8 mm (0.150 in.)
        9 3.9 mm (0.154 in.)
        A 4.0 mm (0.158 in.)
  12. INSPECT CLUTCH HUB SUB-ASSEMBLY 
    1. Using a dial indicator, measure the inside diameter of the clutch hub bushing.

      Standard inside diameter: 26.037 to 26.062 mm (1.0251 to 1.0261 in.) 

      Fig 12: Measuring Inside Diameter Of Forward Clutch Hub Bushing
      G04053413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the inside diameter is greater than the standard inside diameter, replace the clutch hub.

  13. INSPECT NO. 3 CLUTCH DISC 
    1. Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt.

      If necessary, replace them.

      NOTE:
      • If the linings of the discs are peeled off or discolored, or even a part of the printed numbers is damaged, replace all discs.
        Fig 13: Inspecting Disc
        G04019470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Before assembling new discs, soak them in ATF for at least 15 minutes.
  14. INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY 
    1. Using a dial indicator, measure the inside diameter of the reverse clutch hub bushing.

      Standard inside diameter: 35.812 to 35.837 mm (1.4099 to 1.4109 in.) 

      If the inside diameter is greater than the standard inside diameter, replace the reverse clutch hub.

      Fig 14: Measuring Inside Diameter Of Reverse Clutch Hub Bushing
      G04053415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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