UNDERDRIVE Clutch: Installation

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 UNDERDRIVE CLUTCH PISTON SET
1. Coat the underdrive clutch piston with ATF, and install it to the underdrive clutch piston drum.
  NOTE: Be careful not to damage the O-ring.
  
  Fig 1: Identifying Underdrive Clutch Piston To Underdrive Clutch Piston Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the piston return spring to the underdrive clutch drum.
  
  Fig 2: Identifying Piston Return Spring To Underdrive Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the clutch balancer to the underdrive clutch drum.
  NOTE: Be careful not to damage the lip seal of the clutch balancer.
  
  Fig 3: Identifying Clutch Balancer To Underdrive Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place SST on the clutch balancer and compress the piston return spring with a press.
  SST 09350-32014 (09351 -32070)
5. Using a snap ring expander, install the snap ring to the underdrive clutch drum.
  NOTE:
  - Be sure the end gap of the snap ring is not aligned with the clutch balancer's claw.
  - Stop the press when the spring sheet is lowered to a position 1 to 2 mm (0.039 0.078 in.) from the snap ring groove.
  - This prevents the spring sheet from being deformed.
  - Do not expand the snap ring excessively.
    
    Fig 4: Identifying Snap Ring To Underdrive Clutch Drum
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Set the end gap of the snap ring in the underdrive clutch drum shown in the illustration.
  NOTE: The end gap of the snap ring should not coincide with any of the stopper.
  
  Fig 5: Identifying End Gap Of Snap Ring In Underdrive Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE CLUTCH DRUM O-RING
1. Coat the new O-ring with ATF, and install it to the underdrive clutch drum.
  
  Fig 6: Identifying O-Ring To Underdrive Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 UNDERDRIVE CLUTCH DISC
1. Install the 3 plates, 3 discs and flange to the underdrive clutch drum.
  Install in order:
  
  P - D - P - D - P - D - F
  
  HINT:
  
  P = Plate
  
  D = Disc
  
  F = Flange
  
  Fig 7: Identifying Plates, Discs And Flange To Underdrive Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the underdrive clutch flange hole snap ring.
3. Check that the end gap of the snap ring is not aligned with one of the cutouts.

INSPECT UNDERDRIVE CLUTCH PACK CLEARANCE

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

Fig 9: Identifying Dial Indicator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard pack clearance:

1.51 to 1.90 mm (0.0594 to 0.0748 in.)

Fig 10: Identifying Underdrive Clutch Piston Stroke

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble again.

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

HINT:

There are 3 flanges in different thickness.

Standard flange thickness

STANDARD FLANGE THICKNESS

No.	Thickness	No.	Thickness
1	3.0 mm (0.118 in.)	3	3.4 mm (0.134 in.)
2	3.2 mm (0.126 in.)	-	-