Direct Clutch: Reassembly
WARNING: This page does not describe the selected car, but rather 11 other vehicles, including the 1992 Geo Prizm, 1991 Toyota MR2, 1991 Toyota Corolla, 1991 Geo Prizm, and 1990 Toyota Corolla. However, it is still accessible from the selected car via links, so may be relevant.
- Install NEW "O" rings on piston and coat with ATF. Using hand pressure, press direct clutch piston into clutch drum with cup side upward. Use care not to damage "O" rings. Install piston return springs, retainer and snap ring. Compress return springs and retainer using clutch spring compressor.
- Ensure snap ring gap does not align with spring retainer claw. Install plates and discs in reverse order of removal. Install flange with flat side facing downward. Install snap ring. Ensure snap ring gap does not align with drum cutout.
- Install direct clutch on oil pump. Using a dial indicator, measure direct clutch piston stroke. Apply compressed air to oil pump passage and note dial indicator reading. See Fig 2. Refer to DIRECT CLUTCH PISTON STROKE SPECIFICATIONS for stroke specification. If piston stroke is not as specified, select the appropriate flange to obtain the correct piston stroke. Refer to DIRECT CLUTCH FLANGE APPLICATION for flange thicknesses.
DIRECT CLUTCH PISTON STROKE SPECIFICATIONS
| Application | In. (mm) |
|---|---|
| A-240E | .045-.059 (1.13-1.50) |
| A-240L | .054-.067 (1.37-1.70) |
| A-241L & A-241E | .044-.058 (1.11-1.47) |
| A-243L & A-244E | .064-.078 (1.63-1.97) |
DIRECT CLUTCH FLANGE APPLICATION
| Application | In. (mm) |
|---|---|
| A-240E | .102 (2.60), .118 (3.00) & .133 (3.37) |
| A-240L | .118 (3.00) & 1.33 (3.37) |
| A-241E & A-241L | .102 (2.60) & .118 (3.00) |
| A-243L & A-244E | .102 (2.60), .110 (2.80) & .118 (3.00) |