Direct Clutch: Reassembly

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL OVERDRIVE DIRECT CLUTCH O-RING
1. Coat the O-ring with ATF, and install it to the direct clutch drum.
  NOTE: Make sure that the O-ring is not twisted or pinched when it is installed.
  
  Fig 1: Identifying O-Ring From Direct Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OVERDRIVE DIRECT CLUTCH DRUM SUBASSEMBLY
1. Coat the direct clutch drum with ATF, and install it to the intermediate shaft.
  NOTE:
  - Be careful not to damage the O-ring.
  - Be careful not to damage the lip of the direct clutch drum.
    
    Fig 2: Identifying Intermediate Shaft
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OVERDRIVE DIRECT CLUTCH PISTON
1. Coat the overdrive direct clutch piston with ATF, and install it to the direct clutch drum.
  
  Fig 3: Identifying Overdrive Direct Clutch Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Install the overdrive clutch return spring to the direct clutch drum.
  NOTE: After installing the spring sub-assembly, check that all of the springs fit in the piston correctly.
  
  Fig 4: Identifying Overdrive Clutch Return Spring From Direct Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the clutch balancer with ATF.
3. Install the clutch balancer to the direct clutch drum.
  NOTE:
  - Be careful not to damage the lip of the direct clutch balancer.
  - Make sure that the lip of the seal is not pinched and that it has no other defects.
  - Apply sufficient ATF to the sealing lip before installing the clutch balancer.
    
    Fig 5: Identifying Clutch Balancer From Direct Clutch Drum
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place SST on the clutch balancer and compress the overdrive clutch return spring with a press.
  SST 09387-00020
  
  Fig 6: Identifying SST On Clutch Balancer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a snap ring expander, install the snap ring to the direct 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.
7. Set the end gap of the snap ring in the piston shown in the illustration.
  NOTE: The end gap of the snap ring should not align with any of the stoppers.
  
  Fig 7: Identifying Stopper Location
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OVERDRIVE DIRECT CLUTCH DISC
1. Coat the 4 discs with ATF.
2. Install the 4 plates, 4 discs and flange to the intermediate shaft.
  NOTE: Make sure that the plates, discs and flange are installed as shown in the illustration.
  
  Fig 8: Identifying Plates, Discs And Flange To Intermediate Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, install the snap ring.
4. 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.
INSTALL DIRECT MULTIPLE DISC CLUTCH DISC
1. Coat the 3 discs with ATF.
2. Install the cushion plate, 3 plates, 3 discs and flange to the intermediate shaft.
  NOTE:
  - Install the cushion plate with the mark on the white surface facing towards the plate.
  - Be careful of the order of cushion plate discs, plate and flange.
    
    Fig 10: Identifying Cushion Plate, Plates, Discs And Flange To Intermediate Shaft
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, install the snap ring.
4. 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 PACK CLEARANCE OF DIRECT CLUTCH AND OVERDRIVE CLUTCH

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 less than the minimum, parts may have been assembled incorrectly, so check and reassemble them again. If the clearance is not as specified, select another flange.

HINT:

There are 7 different thicknesses of flanges available.

Standard flange thickness

STANDARD FLANGE THICKNESS

No.	Thickness	No.	Thickness
0	2.5 mm (0.098 in.)	4	2.9 mm (0.114 in.)
1	2.6 mm (0.102 in.)	5	3.0 mm (0.118 in.)
2	2.7 mm (0.106 in.)	6	3.1 mm (0.122 in.)
3	2.8 mm (0.110 in.)	-	-

Fig 12: Identifying Direct Clutch And Overdrive Clutch Pack Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PACK CLEARANCE OF REVERSE CLUTCH

Install the intermediate shaft onto the transaxle rear cover.

Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm² , 57 psi).

Standard clearance:

0.60 to 0.82 mm (0.0236 to 0.0323 in.)

If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble them again. If the clearance is not as specified, select another flange.

HINT:

There are 7 different thicknesses of flanges available.

Standard flange thickness

THICKNESS SPECIFICATION CHART

No.	Thickness	No.	Thickness
1	3.0 mm (0.118 in.)	5	3.4 mm (0.134 in.)
2	3.1 mm (0.122 in.)	6	3.5 mm (0.138 in.)
3	3.2 mm (0.126 in.)	7	3.6 mm (0.142 in.)
4	3.3 mm (0.130 in.)	-	-

Fig 13: Identifying Reverse Clutch Pack Clearance

INSPECT DIRECT CLUTCH ASSEMBLY
1. Check that the disc rotates when rotating the disc after inserting the rear planetary sun gear.
  NOTE: Do not place the rear planetary sun gear in a vise.
  
  Fig 14: Identifying Direct Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002