Clutch Drum And Input Shaft Assembly: Inspection

WARNING: This page is about a different variant/trim than selected.

INSPECT NO. 4 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 clockwise and locks counterclockwise. If there is a problem with the one way clutch, replace it.
Fig 1: Inspecting No 4 One Way Clutch Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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:
  
  20.02 mm (0.788 in.)
  
  If the free length is shorter than the standard free length, replace the clutch return spring subassembly.
Fig 2: Measuring Free Length Of Spring Together With Spring Seat
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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:
  
  21.03 mm (0.828 in.)
  
  If the free length is shorter than the standard free length, replace the clutch return spring subassembly.
Fig 3: Measuring Free Length Of Spring Together With Spring Seat
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 DIRECT CLUTCH DISC
1. Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt.
  
  Fig 4: Inspecting Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
  - Before assembling new discs, soak them in ATF for at least 15 minutes.

INSPECT PACK CLEARANCE OF NO. 2 DIRECT CLUTCH

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 to the oil hole as shown in the illustration, and calculate the average.
  HINT:
  
  Flange moving distance A = 0.24 to 1.12 mm (0.0094 to 0.0441 in.)
  
  Pack clearance = Flange moving distance A - 0.03 mm (0.0012 in.)
  
  Pack Clearance:
  
  0.5 to 0.8 mm (0.020 to 0.031 in.)
  
  Fig 5: Checking Moving Distance Of Clutch Flange At Both Ends Across Diameter While Blowing Air To Oil Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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 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 SPECIFICATION

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.)

INSPECT PACK CLEARANCE OF NO. 3 CLUTCH

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: Checking Reverse Clutch Piston Stroke And Moving Distance Of Reverse Clutch Flange At Both Ends Across Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Piston stroke A = 1.62 to 2.68 mm (0.0638 to 0.1055 in.)
  
  Flange moving distance B = 1.22 to 1.67 mm (0.0480 to 0.0657 in.)
  
  Pack clearance = Piston stroke A - Flange moving distance B - 0.02 mm (0.0008 in.)
  
  Pack Clearance:
  
  0.4 to 0.7 mm (0.016 to 0.028 in.)
  
  NOTE: Install a selective flange {t = 2.8 mm (0.110 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 12 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

Flange thickness

FLANGE THICKNESS SPECIFICATION

No.	Thickness
0	2.4 mm (0.094 in.)
1	2.5 mm (0.098 in.)
2	2.6 mm (0.102 in.)
3	2.7 mm (0.106 in.)
4	2.8 mm (0.110 in.)
5	2.9 mm (0.114 in.)
6	3.0 mm (0.118 in.)
7	3.1 mm (0.122 in.)
8	3.2 mm (0.126 in.)
9	3.3 mm (0.130 in.)
A	3.4 mm (0.134 in.)
B	3.5 mm (0.138 in.)

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:
  
  26.29 mm (1.035 in.)
  
  Fig 7: Measuring Free Length Of Spring Together With Spring Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the free length is shorter than the standard free length, replace the clutch return spring subassembly.
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
  Courtesy 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.

INSPECT PACK CLEARANCE OF NO. 1 CLUTCH

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 = 0.14 to 0.17 mm (0.0055 to 0.0067 in.)
  
  Pack clearance = Flange moving distance A - 0.01 mm (0.00039 in.)
  
  Fig 9: Checking Moving Distance Of Clutch Flange At Both Ends Across Diameter While Blowing Air From Oil Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Pack Clearance:
  
  0.56 to 0.86 mm (0.0220 to 0.0339 in.)
  
  NOTE: Install a selective flange {t = 3.5 mm (0.138 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 SPECIFICATION

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.)

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
  Courtesy 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.

INSPECT PACK CLEARANCE OF COAST CLUTCH

Inspect the pack clearance of the coast 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 = 0.02 to 1.01 mm (0.0008 to 0.0398 in.)
  
  Pack clearance = Flange moving distance A - 0.01 mm (0.00039 in.)
  
  Fig 11: Checking Moving Distance Of Clutch Flange At Both Ends Across Diameter While Blowing Air From Oil Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Pack Clearance:
  
  0.4 to 0.7 mm (0.0157 to 0.0276 in.)
  
  NOTE: Install a selective flange {t = 3.5 mm (0.138 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 SPECIFICATION

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.)

INSPECT CLUTCH HUB SUB-ASSEMBLY
1. Using a dial indicator, measure the inside diameter of the clutch hub bushing.
  
  Fig 12: Checking Inside Diameter Of Clutch Hub Bushing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard inside diameter:
  
  23.037 to 23.062 mm (0.907 to 0.908 in.)
  
  If the inside diameter is greater than the standard inside diameter, replace the clutch hub.
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.
  - Before assembling new discs, soak them in ATF for at least 15 minutes.
Fig 13: Inspecting Disc
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY
1. Using a dial indicator, measure the inside diameter of the reverse clutch hub bushing.
  Standard inside diameter:
  
  33.312 to 33.337 mm (1.3115 to 1.3125 in.)
  
  If the inside diameter is greater than the standard inside diameter, replace the reverse clutch hub.
Fig 14: Checking Inside Diameter Of Reverse Clutch Hub Bushing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002