Direct Clutch: Reassembly
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.
- Install NEW "O" rings on piston. Coat rings with ATF. Press piston in drum with cup side up. Ensure "O" ring is not damaged. Install piston return springs. Install retainer and snap ring.
- Using Compressor Block (09351-32070) and an arbor press, compress return springs. See Fig 2. Using snap ring pliers, install snap ring in groove. Ensure end-gap of spring is not aligned with spring retainer claw.
- For A-241H, install in order: plate, disc, plate, plate, disc, and flange. Install flange with flat side facing inward. Install outer snap ring. Ensure end gap of snap ring is not aligned with cut-outs in direct clutch drum.
- Install direct clutch on oil pump. If disc, plate or flange have been replaced, check piston stroke. Using a dial indicator, measure piston stroke by applying and releasing 57-114 psi (4-8 kg/cm2 ) of compressed air. See Fig 1.
- Piston stroke should be .0535-.0669" (1.360-1.710 mm) for A-241H. If piston stroke is less than specification, replace flange.
- Flange is available in 2 thicknesses, .1181" (3.000 mm) or .1327" (3.370 mm) for A-241H.
- Check operation of direct clutch. Apply compressed air to passage of oil pump body. Ensure movement of piston. If piston does not move, disassemble and inspect unit.