Direct Clutch: Disassembly

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 REVERSE CLUTCH (See INSPECTION )
INSPECT PACK CLEARANCE OF DIRECT CLUTCH AND OVERDRIVE CLUTCH (See INSPECTION )
REMOVE DIRECT MULTIPLE DISC CLUTCH DISC
1. Using a screwdriver, remove the snap ring from the intermediate shaft.
  
  Fig 1: Identifying Snap Ring From Intermediate Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the flange, 3 discs, 3 plates and cushion plate from the intermediate shaft.
  
  Fig 2: Identifying Flange, Discs, Plates And Cushion Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OVERDRIVE DIRECT CLUTCH DISC
1. Using a screwdriver, remove the snap ring from the intermediate shaft.
2. Remove the flange, 4 discs and 4 plates from the intermediate shaft.
  
  Fig 3: Identifying Flange, Discs And Plates
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Place SST on the clutch balancer and compress the spring with a press.
  SST 09387-00020
2. Using a snap ring expander, remove the snap ring from the direct clutch drum.
  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.
    
    Fig 4: Identifying Snap Ring From Direct Clutch Drum
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the clutch balancer from the direct clutch drum.
  
  Fig 5: Identifying Clutch Balancer And Direct Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the overdrive clutch return spring from the direct clutch drum.
  
  Fig 6: Identifying Overdrive Clutch Return Spring And Direct Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OVERDRIVE DIRECT CLUTCH PISTON
1. Install the intermediate shaft on the transaxle rear cover.
2. Holding the direct clutch piston with your hand, apply compressed air (392 kPa, 4.0 kgf/cm² , 57 psi) to the transaxle rear cover to remove the direct clutch piston.
REMOVE OVERDRIVE DIRECT CLUTCH DRUM SUBASSEMBLY
1. Holding the direct clutch drum by hand, apply compressed air (392 kPa, 4.0 kgf/cm² , 57 psi) to the transaxle rear cover to remove the direct clutch drum.
  
  Fig 8: Identifying Compressed Air To Transaxle Rear Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OVERDRIVE DIRECT CLUTCH O-RING

Fig 9: Identifying Overdrive Direct Clutch O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a screwdriver, remove the O-ring from the direct clutch drum.