Direct Clutch: Inspection

WARNING: This page is about a different car, the 2007 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

INSPECT PACK CLEARANCE OF DIRECT CLUTCH
1. Install the direct clutch and needle roller bearing on the transaxle rear cover.
2. Using a dial indicator, measure the forward clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm² , 57 psi)
  Standard pack clearance: 0.515 to 0.825 mm (0.0203 to 0.0324 in.)
  
  If the pack clearance is not as specified, inspect the discs, plates and flange.
  
  Fig 1: Measuring Forward Clutch Pack Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIRECT MULTIPLE DISC CLUTCH DISC
1. Check to see if the sliding surface of the disc, plate and flange are worn or burnt.
  If necessary, replace them.
  
  HINT:
  - If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs.
  - Before assembling new discs, soak them in ATF for at least 15 minutes.
    
    Fig 2: Inspecting Direct Multiple Disc Clutch Disc
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Using a vernier caliper, measure the free length of the spring together with the spring seat.
  Standard free length: 22.58 mm (0.8898 in.)
  
  Fig 3: Measuring Free Length Of Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002