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 DIRECT CLUTCH (See INSPECTION )
REMOVE DIRECT MULTIPLE DISC CLUTCH DISC
1. Using a screwdriver, pry out the snap ring from the direct clutch drum.
  
  Fig 1: Identifying Prying Out Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the flange, 3 discs and 3 plates from the direct clutch drum.
INSPECT DIRECT MULTIPLE DISC CLUTCH DISC (See INSPECTION )
REMOVE DIRECT CLUTCH RETURN SPRING SUBASSEMBLY
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.
  HINT:
  - 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 3: Identifying Snap Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the clutch balancer from the direct clutch drum.
  
  Fig 4: Identifying Clutch Balancer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the piston return spring from the direct clutch drum.
  
  Fig 5: Identifying Piston Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the direct clutch drum on the transaxle rear cover.
6. 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.
INSPECT DIRECT CLUTCH RETURN SPRING SUBASSEMBLY (See INSPECTION )