Forward 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 PACK CLEARANCE OF FORWARD CLUTCH
1. Install the forward clutch on the oil pump.
  NOTE: Be careful not to damage the oil seal ring of oil pump.
2. Using a dial indicator, measure the forward clutch piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm² , 57 psi)
  Standard position stroke:
  
  1.74 to 2.08 mm (0.0685 to 0.0819 in.)
  
  Fig 1: Identifying Forward Clutch Piston Stroke
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the piston stroke is less than the minimum, the parts may have been assembled incorrectly. Check and reassemble again.
  
  If the clearance is not as specified, select another flange.
  
  HINT:
  
  As the opening is big, cover it with a shop rag to prevent the compressed air from being discharged.
INSPECT FORWARD MULTIPLE DISC CLUTCH DISC
1. Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them.
  HINT:
  - If the lining of the disc is peeling off or discolored, replace all discs.
  - Before assembling new discs, soak them in ATF for at least 15 minutes.
    
    Fig 2: Identifying Forward Multiple Disc Clutch Disc
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FORWARD 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:
  
  28.23 mm (1.1102 in.)
  
  Fig 3: Identifying Free Length Of Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FORWARD CLUTCH PISTON SUBASSEMBLY
1. Shake the piston to check that the check ball is not stuck.
  
  Fig 4: Identifying Ball For Stuck
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check that air does not leak from the valve when applying low compressed air (392 kPa, 4.0 kgf*cm² , 57 psi)
  
  Fig 5: Identifying Low Compressed Air
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002