UNDERDRIVE Clutch: Disassembly

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 UNDERDRIVE PACK CLEARANCE (See INSPECTION )
REMOVE NO. 1 UNDERDRIVE CLUTCH DISC
1. Using a screwdriver, pry out the snap ring.
  
  Fig 1: Prying Out Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the flange, 3 discs and 3 plates from the underdrive clutch drum.
INSPECT NO. 1 UNDERDRIVE CLUTCH DISC (See INSPECTION )

Fig 2: Removing Flange, Discs And Plates From Underdrive Clutch Drum
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE UNDERDRIVE CLUTCH PISTON SET
1. Place SST on the clutch balancer and compress the spring with a press.
  SST 09350-32014 (09351-32070)
2. Using a snap ring expander, remove the snap ring.
  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.
  - This prevents the spring sheet from being deformed.
  - Do not expand the snap ring excessively.
    
    Fig 3: Removing Snap Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the clutch balancer and piston return spring from the underdrive clutch drum.
  
  Fig 4: Removing Clutch Balancer And Piston Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the underdrive clutch to the transaxle case.
  NOTE: Be careful not to damage the oil seal rings.
  
  Fig 5: Installing Underdrive Clutch To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Holding the underdrive clutch piston with your hand, apply compressed air (392 kPa, 4.0 kgf/cm² , 57 psi) to the transaxle case to remove the underdrive clutch piston.
INSPECT UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY (See INSPECTION )

Fig 6: Applying Compressed Air To Transaxle Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE UNDERDRIVE CLUTCH DRUM O-RING
INSPECT UNDERDRIVE CLUTCH DRUM SUBASSEMBLY (See INSPECTION )

Fig 7: Removing Underdrive Clutch Drum O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002