Direct 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 PACK CLEARANCE OF REVERSE CLUTCH
1. Install the intermediate shaft and needle roller bearing onto the transaxle rear cover.
2. Using a dial indicator, measure the reverse clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm² , 57 psi).
  Standard pack clearance: 0.60 to 0.82 mm (0.0236 to 0.0323 in.)
  
  If the pack clearance is not as specified, inspect the discs, plates and flange.
  
  Fig 1: Measuring Clutch Pack Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PACK CLEARANCE OF DIRECT CLUTCH AND OVERDRIVE CLUTCH
1. Using a dial indicator, measure the direct clutch and overdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm² , 57 psi).
  Standard pack clearance: 0.61 to 0.83 mm (0.0240 to 0.0327 in.)
  
  If the pack clearance is not as specified, inspect the discs, plates and flange.
  
  Fig 2: Measuring Direct Clutch And Overdrive Clutch Pack Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIRECT MULTIPLE DISC CLUTCH DISC
1. Check if the sliding surfaces of the disc, plate and flange are worn or burnt.
  If necessary, replace them.
  NOTE:
  - If the lining of the disc comes off or is discolored, or if a part of the groove is worn, replace all the discs.
  - Before installing new discs, immerse them in ATF for at least 15 minutes.
    
    Fig 3: Checking Sliding Surfaces Of Disc, Plate And Flange
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT OVERDRIVE DIRECT CLUTCH DISC
1. Check if the sliding surface of the disc, plate and flange are worn or burnt.
  If necessary, replace them.
  NOTE:
  - If the lining of the disc comes off or is discolored, or if a part of the groove is worn, replace all the discs.
  - Before installing new discs, immerse them in ATF for at least 15 minutes.
    
    Fig 4: Checking Sliding Surface Of Disc, Plate And Flange
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT OVERDRIVE 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: 25.91 mm (1.0201 in.)
  
  Fig 5: Measuring Free Length Of Spring Together With Spring Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002