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Direct Clutch: Disassembly

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 1994 Toyota MR2, 1993 Toyota MR2, 1993 Toyota Celica, 1992 Toyota MR2, and 1992 Toyota Corolla. However, it is still accessible from the selected car via links, so may be relevant.
  1. Prior to disassembly, check piston stroke of direct clutch. Measure piston stroke by applying 57-114 psi (4-8 kg/cm2 ) of compressed air. See Figure. Piston stroke should be .0535-.0669" (1.360-1.710 mm) for A-241H. If piston stroke is greater than maximum, inspect each component.
  2. Remove snap ring from clutch drum. Remove flange, discs and plates. To compress piston return springs and remove snap ring, place Compressor Block (09351-32070) on spring retainer. Compress springs with an arbor press. See Figure.
  3. Remove spring retainer and 18 springs. Slide direct clutch on oil pump. Remove piston by applying low pressure compressed air. If piston does not completely come out, remove with needle-nose pliers. Remove direct clutch from oil pump. Remove "O" ring from clutch piston. See Figure.
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