UNDERDRIVE Clutch: Inspection

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.

INSPECT UNDERDRIVE PACK CLEARANCE

Install the underdrive clutch to the transaxle case.
NOTE: Be careful not to damage the oil seal rings.
Install a dial indicator as shown in the illustration.

Measure the underdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm² , 57 psi).

Standard pack clearance:

1.51 to 1.71 mm (0.0594 to 0.0673 in.)

If the pack clearance is not as specified, inspect the discs, plates and flange.

HINT:

There are 5 different thicknesses flanges available.

Standard flange thickness

STANDARD FLANGE THICKNESS

Mark	Thickness	Mark	Thickness
1	3.0 mm (0.118 in.)	4	3.6 mm (0.122 in.)
2	3.2 mm (0.126 in.)	5	3.8 mm (0.130 in.)
3	3.4 mm (0.134 in.)	-	-

Fig 1: Identifying Underdrive Clutch Pack Clearance

INSPECT NO. 1 UNDERDRIVE 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 2: Identifying No. 1 Underdrive Clutch Disc
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT UNDERDRIVE CLUTCH DRUM SUBASSEMBLY
1. Using a caliper gauge, measure the inside diameter of the underdrive clutch drum bushing,
  Standard drum bushing:
  
  37.06 to 37.08 mm (1.4591 to 1.4598 in.)
  
  Maximum drum bushing:
  
  37.13 mm (1.4618 in.)
  
  If the inside diameter is greater than the maximum, replace the underdrive clutch drum sub-assembly.
  
  Fig 3: Identifying Inside Diameter Of Underdrive Clutch Drum Bushing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT UNDERDRIVE 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:
  
  17.14 mm (0.6752 in.)
  
  Fig 4: Identifying Free Length Of Spring Together With Spring Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002