Forward 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 INPUT SHAFT OIL SEAL RING
1. Compress the oil seal ring from both sides to reduce dimension A.
  Dimension A: 5.0 mm (0.197 in.)
2. Coat the oil seal ring with ATF and install it to the input shaft.
  
  Fig 1: Compressing Oil Seal Ring From Both Sides
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FORWARD CLUTCH PISTON O-RING
1. Coat 2 new O-rings with ATF, and install them to the forward clutch piston.
  
  Fig 2: Installing O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FORWARD CLUTCH PISTON SUBASSEMBLY
1. Install the forward clutch piston to the forward clutch drum.
  
  Fig 3: Installing Forward Clutch Piston To Forward Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Place the forward clutch return spring onto the forward clutch piston.
  
  Fig 4: Placing Forward Clutch Return Spring Onto Forward Clutch Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place SST on the return spring, and compress the return spring with a press.
  SST 09350-32014 (09351-32070)
3. Install the snap ring with a snap ring expander. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
  NOTE:
  - 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.
    
    Fig 5: Installing Snap Ring With Snap Ring Expander
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - This prevents the spring sheet from being deformed.
  - Do not expand the snap ring excessively.
INSTALL FORWARD CLUTCH FLANGE HOLE SNAP RING
1. Install the 5 plates, 5 discs and flange.
  Install order: P - D - P - D - P - D - P - D - P - D - F
  
  HINT:
  
  P = Plate
  
  D = Disc
  
  F = Flange
  
  Fig 6: Installing Plates, Discs And Flange
  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.
INSPECT PACK CLEARANCE OF FORWARD CLUTCH (See INSPECTION )

Fig 7: Installing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FORWARD MULTIPLE DISC CLUTCH DISC
1. Inspect the clutch disc rotation.
  1. After inserting the multiple disc clutch into the multiple disc clutch hub, rotate the forward clutch and check that the disc lightly rotates.
    NOTE: Do not place the forward clutch in a vise.
    
    Fig 8: Installing Clutch Disc Rotation
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002