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 the oil pump.
2. Using a dial indicator, measure the forward clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm² , 57 psi).
  Standard pack clearance:
  
  1.00 to 1.25 mm (0.0394 to 0.4921 in.)
  
  If the clearance is not as specified, inspect the discs, plates and flange.
  
  HINT:
  
  If the opening is large, cover it with a piece of cloth to prevent the compressed air from being released.
  
  Fig 1: Identifying Forward Clutch Pack Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FORWARD MULTIPLE DISC 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 Sliding Surface Of Disc, Plate And Flange
    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:
  
  26.74 mm (1.0528 in.)
  
  Fig 3: Identifying Free Length Of Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FORWARD MULTIPLE DISC CLUTCH DISC
1. Check if the disc lightly rotates when rotating the forward clutch after inserting the multiple disc clutch into it.
  NOTE: Do not place the forward clutch in a vise.
  
  Fig 4: Identifying Forward Multiple Disc Clutch Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002