UNDERDRIVE 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 UNDERDRIVE CLUTCH DRUM O-RING
1. Coat a new 0-ring with ATF and install it to the underdrive clutch drum.
  
  Fig 1: Identifying Underdrive Clutch Drum O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 2: Identifying Underdrive Clutch Piston SET
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the piston return spring and clutch balancer to the underdrive clutch drum.
  NOTE: Be careful not to damage the lip seal of the clutch balancer.
  
  Fig 3: Identifying Piston Return Spring And Clutch Balancer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place SST on the clutch balancer and compress the piston return spring with a press.
  SST 09350-32014 (09351-32070)
4. Using a snap ring expander, install the snap ring to 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 the place 1 to 2 mm (0.039 to 0.078 in.) from the sap ring groove.
  - This prevents the spring sheet from being deformed.
  - Do not expand the snap ring excessively.
    
    Fig 4: Identifying Snap Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 UNDERDRIVE CLUTCH DISC
1. Install the 3 plates, 3 discs and flange.
  Install in order:
  
  P - D - P - D - P - D - F
  
  HINT:
  
  P = Plate
  
  D = Disc
  
  F = Flange
  
  Fig 5: 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 UNDERDRIVE PACK CLEARANCE

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

Fig 7: 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.)

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

FLANGE THICKNESS SPECIFICATION

No.	Thickness	No.	Thickness
A	3.0 mm (0.118 in.)	C	3.4 mm (0.134 in.)
B	3.2 mm (0.126 in.)	-	-

Fig 8: Identifying Underdrive Clutch Piston Stroke