UNDERDRIVE 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 UNDERDRIVE PACK CLEARANCE
1. Install the underdrive clutch to the transaxle case.
  NOTE: Be careful not to damage the oil seal rings.
2. Install a dial indicator as shown in the illustration.
  
  Fig 1: Installing Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Measure the underdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm² , 57 psi).
  Standard pack clearance: 1.51 to 1.90 mm (0.0594 to 0.0748 in.)
  
  If the pack clearance is not as specified, inspect the discs, plates and flange.
  
  Fig 2: Measuring Underdrive Clutch Pack Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 UNDERDRIVE 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 3: Identifying No. 1 Underdrive Clutch Disc
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT UNDERDRIVE 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: 17.14 mm (0.6748 in.)
  
  Fig 4: Measuring Free Length Of Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT UNDERDRIVE CLUTCH DRUM SUBASSEMBLY
1. Using a caliper gauge, measure the inside diameter of the underdrive clutch drum bush.
  Standard drum bush: 32.56 to 32.58 mm (1.2818 to 1.2826 in.)
  
  Maximum drum bush: 32.63 mm (1.2846 in.)
  
  If the inside diameter is greater than the maximum, replace the underdrive clutch drum sub-assembly.
  
  Fig 5: Measuring Inside Diameter Of Underdrive Clutch Drum Bush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002