UNDERDRIVE 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 UNDERDRIVE CLUTCH DRUM O-RING
1. Coat a new O-ring with ATF and install it to the underdrive clutch drum.
  
  Fig 1: Installing O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE CLUTCH PISTON SET
1. Coat the underdrive clutch piston with ATF, and install it to the underdrive clutch piston drum.
  NOTE: Be careful not to damage the O-ring.
  
  Fig 2: Installing Underdrive Clutch Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the piston return spring and clutch balancer to the underdrive clutch drum.
  NOTE: Be careful not to damage the lip seal of the clutch balancer.
  
  Fig 3: Installing Piston Return Spring And Clutch Balancer To Underdrive Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place SST on the clutch balancer and compress the piston return spring with a press.
  SST 09350-32014 (09351-32070)
4. Using a snap ring expander, install the snap ring to underdrive clutch drum.
  NOTE:
  - Be sure the end gap of the snap ring is not aligned with the clutch balancer's 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 sap ring groove.
    
    Fig 4: Installing Snap Ring To Underdrive Clutch Drum
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - This prevents the spring sheet from being deformed.
  - Do not expand the snap ring excessively.
INSTALL NO. 1 UNDERDRIVE CLUTCH DISC
1. Install the 3 plates, 3 discs and flange.
  Install in order: P - D - P - D - P - D - F
  
  HINT:
  
  P = Plate
  
  D = Disc
  
  F = Flange
  
  Fig 5: 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 UNDERDRIVE PACK CLEARANCE

Install the underdrive clutch to the transaxle case.
NOTE: Be careful not to damage the oil seal rings.

Fig 6: Installing Underdrive Clutch To Transaxle Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Set a dial indicator as shown in the illustration.

Fig 7: Setting Dial Indicator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Measure the underdrive clutch piston stroke 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 less than the minimum, parts may have been assembled incorrectly, so check and reassemble again.

If the park clearance is not as specified, select another flange.

HINT:

There are 3 flanges in different thickness.

Standard flange thickness

Fig 8: Measuring Underdrive Clutch Piston Stroke

STANDARD FLANGE THICKNESS SPECIFICATION

No.	Thickness	No.	Thickness
A	3.0 mm (0.118 in.)	C	3.4 mm (0.134 in.)
B	3.2 mm (0.126 in.)	-	-