Forward 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 INPUT SHAFT OIL SEAL RING
1. Compress a new input shaft oil seal ring from both sides to reduce dimension A.
  Dimension A:
  
  5.0 mm (0.197 in.)
2. Coat the oil seal ring with ATF and install it to the forward clutch drum.
  NOTE: Do not expand the end gap of the oil seal ring too much. Fix the hooks firmly.
  
  Fig 1: Identifying Input Shaft Oil Seal Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FORWARD CLUTCH PISTON SUBASSEMBLY
1. Coat the forward clutch piston with ATF, and install it to the forward clutch drum.
  NOTE: Be careful not to damage the lip of the forward clutch piston.
  
  Fig 2: Identifying Forward Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Install the return spring to the forward clutch drum.
  NOTE: After installing the spring, check that all of the springs fit in the piston correctly.
  
  Fig 3: Identifying Forward Clutch Return Spring From Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the clutch balancer with ATF.
3. Install the clutch balancer to the forward clutch drum.
  NOTE:
  - Be careful not to damage the lip of the forward clutch balancer.
  - Make sure that the clutch balancer is not pinched and that there are no other defects on the lip.
  - Apply sufficient ATF to the sealing lip before installation.
    
    Fig 4: Identifying Clutch Balancer From Forward Clutch Drum
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place SST on the clutch balancer, and compress the clutch balancer with a press.
  SST 09387-00020
5. Install the snap ring with a snap ring expander.
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 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 FORWARD MULTIPLE DISC CLUTCH DISC
1. Coat the 5 discs with ATF.
2. Install the 5 plates, 5 discs and flange to the forward clutch drum.
  NOTE: Make sure that the plates, discs, and flange are installed as shown in the illustration.
  
  Fig 7: Identifying Plates, Discs And Flange Location Forward Clutch Drum
  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 FORWARD CLUTCH

Using a dial indicator, measure the forward clutch pack clearance while applying and releasing compressed air (392 kgf/cm² , 4.0 kPa, 57 psi). Pack clearance: 1.00 to 1.25 mm (0.0394 to 0.4921 in.)

If the piston stroke is less than the minimum, parts may be assembled incorrectly. Check and reassemble the parts again.

If the clearance is not as specified, select another flange.

HINT:

There are 5 different thicknesses of flanges available.

Standard flange thickness

STANDARD FLANGE THICKNESS

No.	Thickness	No.	Thickness
1	3.00 mm (0.1181 in.)	4	3.45 mm (0.1358 in.)
2	3.15 mm (0.1240 in.)	5	3.60 mm (0.1417 in.)
3	3.30 mm (0.1299 in.)	-	-

Fig 9: Identifying Forward Clutch Pack Clearance

INSPECT FORWARD MULTIPLE DISC CLUTCH DISC (See INSPECTION )