Clutch Drum And Input Shaft Assembly: Inspection

1. Hold the coast clutch hub and turn the one way clutch assembly.
   Fig 1: Checking One Way Clutch Assembly Turns Freely Counterclockwise & Locks Clockwise

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2. Check that the one way clutch assembly turns freely counterclockwise and locks clockwise. If there is a problem with the one way clutch, replace it.

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 Using Vernier Calipers

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

If the free length is shorter than the standard free length, replace the clutch return spring sub-assembly.

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

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

If the free length is shorter than the standard free length, replace the clutch return spring sub-assembly.

1. Check whether the sliding surfaces of the 4 discs, the 5 plates, and the flange are worn or burnt.

   If necessary, replace them.

   Fig 4: Inspecting No. 2 Direct Clutch Disc

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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 from the oil hole as shown in Fig 5, and calculate the average.

      HINT:

      Fig 5: Inspecting Pack Clearance Of No. 2 Direct Clutch

      Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

      Flange moving distance A = 0.25 to 1.08 mm (0.0098 to 0.0425 in.)

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

      Pack Clearance: 0.4 to 0.7 mm (0.0157 to 0.0276 in.) 

      NOTE: Install a selective flange {t = 3.4 mm (0.134 in.)} when measuring the moving distance (shaded area in Fig 5 ).
   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 

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 Fig 6, and calculate the average.
      Fig 6: Inspecting Pack Clearance Of No. 3 Clutch

      Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

      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 (0.0284 to 0.0425 in.)

      Pack clearance = Piston stroke A - Flange moving distance B - 0.06 mm (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 (0.130 in.)} when measuring the moving distance (shaded area in Fig 6 ).
   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 

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 sub-assembly.

Fig 7: Measuring Free Length Of Spring Together With Spring Seat

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1. Check whether the sliding surfaces of the 3 discs, the 3 plates and the flange are worn or burnt. If necessary, replace them.

Fig 8: Inspecting Coat Clutch Disc

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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 Fig 9, and calculate the average.

      HINT:

      Flange moving distance A = 0.38 to 1.48 mm (0.0150 to 0.0583 in.)

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

      Fig 9: Inspecting Pack Clearance Of Coast Clutch

      Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

      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 Fig 9 ).
   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 

1. Check whether the sliding surfaces of the 4 discs, the 5 plates, and the flange are worn or burnt. If necessary, replace them.

Fig 10: Inspecting No. 1 Clutch Disc

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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.)

      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 Fig 11 ).
      Fig 11: Inspecting Pack Clearance Of No. 1 Clutch

      Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
   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 SPECIFICATIONS
   
   

   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.)

1. Using a dial indicator, measure the inside diameter of the forward 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 Using Dial Indicator

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

1. Check whether the sliding surfaces of the 5 discs, the 4 plates, and the flange are worn or burnt. If necessary, replace them.

Fig 13: Inspecting No. 3 Clutch Disc

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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 Using Dial Indicator

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.