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 UNDERDRIVE CLUTCH FLANGE NO. 2 HOLE SNAP RING
1. Using a screwdriver, remove the snap ring.
  
  Fig 1: Removing Underdrive Clutch Flange No. 2 Hole Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 UNDERDRIVE CLUTCH DISC
1. Remove the flange, 4 discs and 4 plates from the underdrive clutch drum.
  
  Fig 2: Removing No. 1 Underdrive Clutch Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Place SST on the clutch balancer and compress the spring with a press.
  SST 09350-32014
2. Using a snap ring expander, remove the snap ring.
  NOTE:
  - Stop the press when the spring seat is lowered to a position 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove. This prevents the spring seat 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 from the underdrive clutch drum.
  
  Fig 4: Removing Clutch Balancer From Underdrive Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the return spring from the underdrive clutch drum.
  
  Fig 5: Removing Return Spring From Underdrive Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE UNDERDRIVE CLUTCH PISTON SET
1. Install the underdrive clutch to the transaxle case.
  NOTE: Be careful not to damage the oil seal ring.
2. Holding the underdrive clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm² , 57 psi) to the transaxle case to remove the underdrive clutch piston.
  
  Fig 6: Removing Underdrive Clutch Piston Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE UNDERDRIVE CLUTCH DRUM O-RING
1. Using a screwdriver, remove the O-ring from the underdrive clutch drum.
  
  Fig 7: Removing O-Ring From Underdrive Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002