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Clutch Drum And Input Shaft Assembly: Inspection

WARNING: This page is about a different car, the 2006 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSPECT REAR CLUTCH DISC 
    1. Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage.
      NOTE: Before assembling new discs, soak them in ATF for at least 15 minutes.
      Fig 1: Inspecting Clutch Disc
      G04436895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY 
    1. Using a caliper gauge, measure the inside diameter of the reverse clutch hub bushing.

      Standard drum bushing: 35.812 to 35.837 mm (1.4099 to 1.4109 in.) 

      Maximum drum bushing: 35.887 mm (1.4129 in.) 

      If the inside diameter is greater than the maximum, replace the reverse clutch hub.

      Fig 2: Measuring Inside Diameter Of Reverse Clutch Hub Bushing Using Caliper Gauge
      G04436891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT FORWARD CLUTCH HUB SUB-ASSEMBLY 
    1. Using a caliper gauge, measure the inside diameter of the forward clutch hub bushing.

      Standard drum bushing: 26.037 to 26. 062 mm (1.0251 to 1.0261 in.) 

      Maximum drum bushing: 26.112 mm (1.0280 in.) 

      If the inside diameter is greater than the maximum, replace the forward clutch hub.

      Fig 3: Measuring Inside Diameter Of Forward Clutch Hub Bushing Using Caliper Gauge
      G04436892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC 
    1. Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage.
      NOTE: Before assembling new discs, soak them in ATF for at least 15 minutes.
      Fig 4: Inspecting Clutch Disc
      G04436895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. 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 (1.053 in.) 

      Fig 5: Measuring Free Length Of Forward Clutch Return Spring Using Vernier Caliper
      G04436894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSPECT DIRECT CLUTCH DISK 
    1. Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage.
      NOTE: Before assembling new discs, soak them in ATF for at least 15 minutes.
      Fig 6: Inspecting Clutch Disc
      G04436895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSPECT REVERSE 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: 21.04 mm (0.828 in.) 

      Fig 7: Measuring Free Length Of Reverse Clutch Return Spring Using Vernier Caliper
      G04436896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSPECT DIRECT 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: 19.51 mm (0.768 in.) 

      Fig 8: Measuring Free Length Of Direct Clutch Return Spring Using Vernier Caliper
      G04436897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSPECT PACK CLEARANCE OF DIRECT CLUTCH 
    1. Using a dial gauge, measure the moving distance (distance A) of the clutch flange at both ends across a diameter while blowing air from the oil hole as shown in Fig 9 , and calculate the average.

      Pack clearance: 0.5 to 0.8 mm (0.020 to 0.031 in.) 

      NOTE: Install a selective flange (3.4 mm (0.134 in.)) when measuring the moving distance (shaded area in Fig 9 .)

      HINT:

      Flange moving distance A = 0.26 to 1.14 mm (0.010 to 0.045 in.)

      Pack clearance = Flange moving distance A - 0.05 mm (0.002 in.)

    2. If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

      Standard flange thickness 

      FLANGE THICKNESS SPECIFICATION

      No. Thickness No. Thickness
      0 3.0 mm (0.118 in.) 5 3.5 mm (0.138 in.)
      1 3.1 mm (0.122 in.) 6 3.6 mm (0.142 in.)
      2 3.2 mm (0.126 in.) 7 3.7 mm (0.146 in.)
      3 3.3 mm (0.130 in.) 8 3.8 mm (0.150 in.)
      4 3.4 mm (0.134 in.) - -
      Fig 9: Measuring Pack Clearance Of Direct Clutch
      G04436898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSPECT PACK CLEARANCE OF REVERSE CLUTCH 
    1. Using a dial gauge, measure the reverse clutch piston stroke (distance A) and the moving distance (distance B) of the reverse flange at the both ends across a diameter while blowing air (392 kPa, 4 kgf/cm2 , 57 psi) from the oil hole as shown, and calculate the average.

      Pack clearance: 0.5 to 0.8 mm (0.020 to 0.031 in.) 

      NOTE: Install a selective flange (3.3 mm (0.130 in.)) when measuring the moving distance (shaded area.)

      HINT:

      Piston stroke A = 1.05 to 2.15 mm (0.041 to 0.085 in.)

      Flange moving distance B = 0.72 to 1.08 mm (0.029 to 0.043 in.)

      Pack clearance = Piston stroke A to Flange moving distance B to 0.06 mm (0.002 in.)

      Fig 10: Measuring Pack Clearance Of Reverse Clutch
      G04436899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

      Standard flange thickness 

      FLANGE THICKNESS SPECIFICATION

      No. Thickness No. Thickness
      0 2.8 mm (0.110 in.) 6 3.4 mm (0.134 in.)
      1 2.9 mm (0.114 in.) 7 3.5 mm (0.138 in.)
      2 3.0 mm (0.118 in.) 8 3.6 mm (0.142 in.)
      3 3.1 mm (0.122 in.) 9 3.7 mm (0.146 in.)
      4 3.2 mm (0.126 in.) A 3.8 mm (0.150 in.)
      5 3.3 mm (0.130 in.) - -
  11. INSPECT PACK CLEARANCE OF FORWARD CLUTCH 
    1. Using a dial gauge, measure the moving distance (distance A) of the clutch flange at boths end across a diameter while blowing air from the oil hole as shown in Fig 11 , and calculate the average.

      Standard pack clearance: 0.6 to 0.9 mm (0.024 to 0.354 in.) 

      NOTE: Install a selective flange (3.4 mm (0.134 in.)) when measuring the moving distance (shaded area in Fig 11 .)

      HINT:

      Flange moving distance A = 0.26 to 1.36 mm (0.010 to 0.054 in.)

      Pack clearance = Flange moving distance A to 0.01 mm (0.0003 in.)

    2. If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

      Standard flange thickness 

      FLANGE THICKNESS SPECIFICATION

      No. Thickness No. Thickness
      0 3.0 mm (0.118 in.) 6 3.6 mm (0.142 in.)
      1 3.1 mm (0.122 in.) 7 3.7 mm (0.146 in.)
      2 3.2 mm (0.126 in.) 8 3.8 mm (0.150 in.)
      3 3.3 mm (0.130 in.) 9 3.9 mm (0.154 in.)
      4 3.4 mm (0.134 in.) A 4.0 mm (0.158 in.)
      5 3.5 mm (0.138 in.) - -
      Fig 11: Measuring Pack Clearance Of Forward Clutch
      G04436900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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