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 the oil seal ring from both sides to reduce dimension A.
  Standard dimension A:
  
  5 mm (0.197 in.)
  
  Fig 1: Identifying Oil Seal Ring From Both Sides
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the oil seal ring with ATF and install it to the input shaft.
INSTALL FORWARD CLUTCH PISTON SUBASSEMBLY
1. Coat 2 new O-rings with ATF, and install them to the forward clutch piston.
  
  Fig 2: Identifying O-Rings To Forward Clutch Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the forward clutch piston to the forward clutch drum.
  
  Fig 3: Identifying Forward Clutch Piston To Forward Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Place the return spring onto the piston.
  SST 09350-32014 (09351 -32070)
  
  Fig 4: Identifying Return Spring Onto Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place SST on the return spring, and compress the return spring with a press.
3. Install the snap ring with a snap ring expander. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
  NOTE:
  - Stop the press when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove.
  - This prevents the spring sheet from being deformed.
  - Do not expand the snap ring excessively.
    
    Fig 5: Identifying Snap Ring With Snap Ring Expander
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. 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 coincide with any of the stoppers.
  
  Fig 6: Identifying End Gap Of Snap Ring In Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FORWARD MULTIPLE DISC CLUTCH DISC
1. Install the 5 plates, 5 discs and flange.
  Install in order:
  
  P - D - P - D - P - D - P - D - P - D - F
  
  HINT:
  
  P = Plate
  
  D = Disc
  
  F = Flange
  
  Fig 7: Identifying Plates, Discs And Flange
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the snap ring.
3. Check that the end gap of the snap ring is not aligned with one of the cutouts.

INSPECT PACK CLEARANCE OF FORWARD CLUTCH

Install the forward clutch on the oil pump.
NOTE: Be careful not to damage the oil seal ring of the oil pump.

Using a dial indicator, measure the forward clutch piston stroke while applying and releasing compressed air (392 kgf/cm² , 4.0 kPa, 57 psi)

Standard piston stroke:

1.74 to 2.08 mm (0.0685 to 0.0819 in.)

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

Fig 9: Identifying Pack Clearance Of Forward Clutch

NOTE: There are 5 different flanges in thickness. 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.)	-	-

INSPECT FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC
1. Inspect the clutch disc rotation.
  1. After inserting the multiple disc clutch into the multiple disc clutch hub, rotate the forward clutch and check that the disc lightly rotates.
    NOTE: Do not place the forward clutch in a vise.
    
    Fig 10: Identifying Clutch Disc Rotation
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002