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.
  NOTE: Make sure that the O-ring is not twisted or pinched.
  
  Fig 1: Installing Underdrive Clutch Drum 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.
  - Be careful not to damage the lip of the piston.
    
    Fig 2: Installing Underdrive Clutch Piston Set
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Install the return spring to the underdrive clutch drum.
  NOTE: After installing the spring sub-assembly, check that all of the springs fit in the piston correctly.
2. Coat the clutch balancer with ATF.
  
  Fig 3: Installing Return Spring To Underdrive Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the clutch balancer to the underdrive clutch drum.
  NOTE: Be careful not to damage the lip of the clutch balancer.
  
  Fig 4: Installing Clutch Balancer To Underdrive Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place SST on the clutch balancer and compress the piston return spring with a press.
  SST 09350-32014 (09351-32070)
5. Using a snap ring expander, install the snap ring to the underdrive clutch drum.
6. Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
  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 5: Installing Snap Ring To Underdrive Clutch Drum
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Set the end gap of the snap ring in the underdrive clutch drum as shown in the illustration.
  NOTE: The end gap of the snap ring should not align with any of the stoppers.
  
  Fig 6: Identifying Stoppers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 UNDERDRIVE CLUTCH DISC
1. Coat the 4 discs with ATF.
2. Install the 4 plates, 4 discs and flange to the underdrive clutch drum.
  NOTE: Make sure that the plates, discs and flange are installed as shown in the illustration.
  
  Fig 7: Identifying Underdrive Clutch Drum Plate, Disc And Flange Configuration
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SHAFT SNAP RING
1. Using a screwdriver, install the underdrive clutch flange hole snap ring.
2. Check that the end gap of the snap ring is not aligned with one of the cutouts.
  NOTE: The snap ring should be fully engaged in the groove of the drum.
INSPECT UNDERDRIVE PACK CLEARANCE (See INSPECTION )

Fig 8: Installing Underdrive Clutch Flange Hole Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002