Direct Clutch: Reassembly

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.

INSTALL DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Coat the direct clutch piston with ATF, and install it to the direct clutch drum.
  NOTE: Be careful not to damage the lip seal of the direct clutch piston.
  
  Fig 1: Installing Direct Clutch Return Spring Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the piston return spring to the direct clutch drum.
  
  Fig 2: Installing Piston Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the clutch balancer to the direct clutch drum.
  NOTE: Be careful not to damage the lip seal of the direct clutch balancer.
  
  Fig 3: Installing Clutch Balancer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place SST on the clutch balancer and compress the piston return spring with a press.
  SST 09387-00020
5. Using a snap ring expander, install the snap ring to the direct clutch drum.
  
  Fig 4: Removing/Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be sure the end gap of the snap ring is not aligned with the clutch balancer claw.
  - Stop the press when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove.
  - This prevents the spring sheet from being deformed.
  - Do not expand the snap ring excessively.
INSTALL DIRECT MULTIPLE DISC CLUTCH DISC
1. Install the 3 plates, 3 discs and flange to the direct clutch drum.
  Install in order: P - D - P - D - P - D - F
  
  HINT:
  
  P = Plate
  
  D = Disc
  
  F = Flange
  
  Fig 5: Installing Direct Multiple Disc Clutch Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the snap ring.
3. Check that the end gap of the snap ring is not aligned with one of the cutouts.
  
  Fig 6: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PACK CLEARANCE OF DIRECT CLUTCH

Install the direct clutch on the transaxle rear cover.

Using a dial indicator, measure the direct 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 less than the minimum, parts may have been assembled incorrectly, so check and reassemble again.

If the stroke is not as specified, select another flange.

HINT:

There are 6 flanges in different thickness.

Fig 7: Measuring Direct Clutch Pack Clearance

Standard flanges in different thickness

FLANGES IN DIFFERENT THICKNESS

No.	Thickness	No.	Thickness
1	3.0 mm (.118 in.)	4	3.3 mm (0.130 in.)
2	3.1 mm (0.122 in.)	5	3.4 mm (0.134 in.)
3	3.2 mm (0.126 in.)	6	3.5 mm (0.138 in.)

INSPECT DIRECT MULTIPLE DISC CLUTCH DISC
1. Check that the disc rotates when rotating the disc after inserting the rear planetary sun gear.
  NOTE: Do not place the rear planetary sun gear in a vise.
  
  Fig 8: Inspecting Direct Multiple Disc Clutch Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002