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Clutch Drum And Input Shaft Assembly: Disassembly

WARNING: This page is about a different car, the 2008 Lexus IS 350. However, it is still accessible from the selected car via links, so may be relevant.
  1. FIX CLUTCH DRUM AND INPUT SHAFT 
    1. Place the oil pump onto the torque converter clutch, and then place the reverse clutch drum sub-assembly and input shaft onto the oil pump.
      Fig 1: Identifying Torque Converter Clutch And Oil Pump
      G05295070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. 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 Reverse Clutch Hub Sub-Assembly Snap Ring
      G05295071Courtesy 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: Identifying Reverse Clutch Hub Sub-Assembly
      G05295072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE REVERSE CLUTCH REACTION SLEEVE 
    1. Remove the reverse clutch reaction sleeve from the reverse clutch hub sub-assembly.
      Fig 4: Identifying Reverse Clutch Reaction Sleeve
      G05295073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. 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.
      2. Fig 5: Identifying Clutch Cushion Plate, Reverse Clutch Flange, Plates And Discs
      G05317998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSPECT NO. 3 CLUTCH DISC  (See INSPECTION  )
  6. INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY  (See INSPECTION  )
  7. REMOVE CLUTCH HUB SUB-ASSEMBLY 
    1. Remove the clutch hub sub-assembly and thrust washer from the reverse clutch drum sub-assembly.
      Fig 6: Identifying Clutch Hub Sub-Assembly And Thrust Washer
      G05295075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 thrust needle roller bearings from the clutch hub sub-assembly.
      3. Fig 7: Identifying Thrust Needle Roller Bearings
      G05824506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSPECT CLUTCH HUB SUB-ASSEMBLY  (See INSPECTION  )
  9. REMOVE COAST CLUTCH HUB SUB-ASSEMBLY 
    1. Remove the coast clutch hub sub-assembly from the reverse clutch drum sub-assembly.
      2. Fig 8: Identifying Coast Clutch Hub Sub-Assembly
      G05295077Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSPECT UNDERDRIVE ONE WAY CLUTCH ASSEMBLY  (See INSPECTION  )
  11. 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 One Way Clutch Assembly, Clutch Hub Thrust Washer And Thrust Bearing Race
      G05295078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE NO. 1 CLUTCH DISC 
    1. Using a screwdriver, remove the hole snap ring.
      Fig 10: Removing No. 1 Clutch Disc Hole Snap Ring
      G05295079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, cushion plate, 4 discs and 4 plates from the input shaft.
  13. INSPECT NO. 1 CLUTCH DISC  (See INSPECTION  )
    Fig 11: Identifying Flange, Cushion Plate, Discs And Plates
    G05295080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE COAST CLUTCH DISC 
    1. Using a screwdriver, remove the hole snap ring.
      Fig 12: Removing Coast Clutch Disc Hole Snap Ring
      G05824511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, the 3 discs and the 3 plates from the input shaft.
      3. Fig 13: Identifying Flange, Discs And Plates
      G05824512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSPECT COAST CLUTCH DISC  (See INSPECTION  )
  16. REMOVE INPUT SHAFT 
    1. Remove the thrust needle roller bearing from the input shaft.
      Fig 14: Identifying Thrust Needle Roller Bearing
      G05824513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the input shaft from the reverse clutch drum sub-assembly.
      Fig 15: Identifying Input Shaft
      G05295084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the thrust needle roller bearing and thrust bearing race from the reverse clutch drum sub-assembly.
      Fig 16: Identifying Thrust Needle Roller Bearing And Thrust Bearing Race
      G05824515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE INPUT SHAFT OIL SEAL RING 
    1. Remove the 4 oil seal rings from the input shaft.
      Fig 17: Identifying Oil Seal Rings
      G05295086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. 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 With SST
      G05295087Courtesy 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
      G05295088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the D-ring from the No. 1 clutch balancer.
  19. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY  (See INSPECTION  )
    Fig 20: Identifying No. 1 Clutch Balancer And D-Ring
    G05295089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE FORWARD CLUTCH PISTON SUB-ASSEMBLY 
    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 Compressed Air To Input Shaft
      G05295090Courtesy 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
      G05295091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE REVERSE CLUTCH FLANGE 
    1. Remove the reverse clutch flange from the reverse clutch drum sub-assembly.
      Fig 23: Identifying Reverse Clutch Flange
      G05295092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. 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 No. 2 Direct Clutch Disc Hole Snap Rings
      G05295093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the direct clutch flange, the 6 plates and the 5 discs from the reverse clutch drum sub-assembly.
      3. Fig 25: Identifying Direct Clutch Flange, Plates And Discs
      G05110415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSPECT NO. 2 DIRECT CLUTCH DISC  (See INSPECTION  )
  24. 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 No. 3 Clutch Balancer Snap Ring
      G05295095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Remove the reverse clutch return spring and the O-ring from the reverse clutch piston.
      2. Fig 27: Identifying Reverse Clutch Return Spring And O-Ring
      G05295096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY  (See INSPECTION  )
  27. REMOVE REVERSE CLUTCH PISTON SUB-ASSEMBLY 
    1. Remove the reverse clutch piston sub-assembly from the reverse clutch drum sub-assembly.
      Fig 28: Identifying Reverse Clutch Piston Sub-Assembly
      G05295097Courtesy 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
      G05295098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the O-ring from the reverse clutch drum sub-assembly.
      Fig 30: Identifying Reverse Clutch Drum Sub-Assembly O-Ring
      G05295099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. 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: Removing Direct Clutch Piston Snap Ring
      G05295711Courtesy 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: Removing Direct Clutch Piston Sub-Assembly
      G05295101Courtesy 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: Identifying No. 2 Clutch Balancer And Direct Clutch Return Spring Sub-Assembly
      G05295102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 2 O-rings from the direct clutch piston sub-assembly.
      6. Fig 34: Identifying Direct Clutch Piston O-Rings
      G05295103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY  (See INSPECTION  )
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