Clutch Drum And Input Shaft Assembly: Inspection

1. Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage.

Fig 1: Identifying Rear Clutch Disc

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1. Using a caliper gauge, measure the inside diameter of the reverse clutch hub bushing.

Standard drum bushing: 35.812 to 35.837 mm (1.4099 to 1.4109 in.) 

Maximum drum bushing: 35.887 mm (1.4129 in.) 

If the inside diameter is greater than the maximum, replace the reverse clutch hub.

Fig 2: Measuring Inside Diameter Of Reverse Clutch Hub Bushing

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1. Using a caliper gauge, measure the inside diameter of the forward clutch hub bushing.

   Standard drum bushing: 26.037 to 26. 062 mm (1.0251 to 1.0261 in.) 

   Maximum drum bushing: 26.112 mm (1.0280 in.) 

   If the inside diameter is greater than the maximum, replace the forward clutch hub.

   Fig 3: Measuring Inside Diameter Of Forward Clutch Hub Bushing

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1. Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage.

Fig 4: Identifying Clutch Disc

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1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length: 26.74 mm (1.053 in.) 

Fig 5: Measuring Free Length Of Forward Clutch Return Spring

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1. Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage.

Fig 6: Identifying Direct Clutch Disc

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1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length: 21.04 mm (0.828 in.) 

Fig 7: Measuring Free Length Of Reverse Clutch Return Spring

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1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

   Standard free length: 19.51 mm (0.768 in.) 

   Fig 8: Measuring Free Length Of Direct Clutch Return Spring

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1. Using a dial gauge, measure the moving distance (distance A) of the clutch flange at both ends across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.

   Pack clearance: 0.5 to 0.8 mm (0.020 to 0.031 in.) 

   NOTE: Install a selective flange (3.4 mm (0.134 in.)) when measuring the moving distance (shaded area in the illustration.)
   Fig 9: Measuring Moving Distance Of Clutch Flange

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   HINT:

   Flange moving distance A = 0.26 to 1.14 mm (0.010 to 0.045 in.)

   Pack clearance = Flange moving distance A - 0.05 mm (0.002 in.)

2. If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

Standard flange thickness 

1. Using a dial gauge, measure the reverse clutch piston stroke (distance A) and the moving distance (distance B) of the reverse flange at the both ends across a diameter while blowing air (392 kPa, 4 kgf/cm² , 57 psi) from the oil hole as shown in the illustration, and calculate the average.

   Pack clearance: 0.5 to 0.8 mm (0.020 to 0.031 in.) 

   NOTE: Install a selective flange (3.3 mm (0.130 in.)) when measuring the moving distance (shaded area in the illustration.)

   HINT:

   Piston stroke A = 1.05 to 2.15 mm (0.041 to 0.085 in.)

   Flange moving distance B = 0.72 to 1.08 mm (0.029 to 0.043 in.)

   Pack clearance = Piston stroke A to Flange moving distance B to 0.06 mm (0.002 in.)

   Fig 10: Measuring Reverse Clutch Piston Stroke And Moving Distance Of Reverse Flange

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

Standard flange thickness 

1. Using a dial gauge, measure the moving distance (distance A) of the clutch flange at both end across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.

   Standard pack clearance: 0.6 to 0.9 mm (0.024 to 0.354 in.) 

   NOTE: Install a selective flange (3.4 mm (0.134 in.)) when measuring the moving distance (shaded area in the illustration.)

   HINT:

   Flange moving distance A = 0.26 to 1.36 mm (0.010 to 0.054 in.)

   Pack clearance = Flange moving distance A to 0.01 mm (0.0003 in.)

   Fig 11: Measuring Moving Distance Of Clutch Flange

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

Standard flange thickness