Clutch Drum And Input Shaft Assembly: Reassembly

INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY
1. Coat 2 new O-rings with ATF, and install them in the direct clutch piston.
  
  Fig 1: Identifying O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the No. 2 clutch balancer and direct clutch return spring to the direct clutch piston.
  
  Fig 2: Identifying No. 2 Clutch Balancer Direct Clutch Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat a new O-ring with ATF, and install them on the clutch drum sub-assembly.
4. Be careful not to damage the O-rings. Press in the direct clutch piston into the clutch drum with both hands.
  
  Fig 3: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Place SST on the direct clutch piston, and compress the return spring with a press.
  SST 09320-89010, 09350-30020 (09350-07070)
6. Install the snap ring with a snap ring expander.
  NOTE:
  - Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
  - Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.
  - Do not expand the snap ring excessively.
    
    Fig 4: Applying Compression To Return Spring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Set the end gap of the snap ring in the piston as shown in the illustration.
  
  Fig 5: Identifying End Gap Of Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY
1. Coat a new O-ring with ATF, and install it on the clutch drum.
  
  Fig 6: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat a new O-ring with ATF, and install it on the reverse clutch piston.
  
  Fig 7: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Be careful not to damage the O-ring. Press in the clutch drum sub-assembly into the reverse clutch piston with both hands.
  
  Fig 8: Identifying Reverse Clutch Piston, Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Coat a new O-ring with ATF, and install it on the reverse clutch piston.
2. Install the reverse clutch return spring onto the reverse clutch piston.
  
  Fig 9: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 3 CLUTCH BALANCER
1. Place SST on the No. 3 clutch balancer, and compress the clutch balancer with a press.
  SST 09387-00070, 09350-30020 (09350-07070)
2. Install the snap ring with a snap ring expander.
3. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
  NOTE:
  - Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.
  - Do not expand the snap ring excessively.
    
    Fig 10: Compressing No. 3 Clutch Balancer, And Compress Return Spring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Set the end gap of the snap ring in the piston as shown in the illustration.
  
  Fig 11: Setting End Gap Of Snap Ring In Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT CLUTCH DISK
1. Install the reverse clutch flange, 6 plates and 5 discs on the clutch drum.
  Install in order: P-P-D-P-D-P-D-P-D-P-D-P-D-F
  
  HINT:
  
  P = Plate, D = Disc, F = Flange
  
  Fig 12: Identifying Reverse Clutch Flange, Plates And Discs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the 2 hole snap rings on the clutch drum.
INSPECT PACK CLEARANCE OF DIRECT CLUTCH (See INSPECTION )

Fig 13: Installing Hole Snap Rings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE CLUTCH FLANGE
1. Install the reverse clutch flange to the clutch drum.
  
  Fig 14: Identifying Reverse Clutch Flange
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE CLUTCH REACTION SLEEVE
1. Install the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates to the reverse clutch hub.
2. Using a screwdriver, install the hole snap ring.
INSPECT PACK CLEARANCE OF REVERSE CLUTCH (See INSPECTION )

Fig 15: Identifying Reverse Clutch Reaction Sleeve, Clutch Cushion Plate
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE CLUTCH REACTION SLEEVE
1. Using a screwdriver, remove the snap ring from the clutch drum.
  
  Fig 16: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates from the reverse clutch hub.
  
  Fig 17: Identifying Reverse Clutch Reaction Sleeve, Clutch Cushion Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FORWARD CLUTCH PISTON
1. Coat 2 new O-rings with ATF, and install them on the No. 1 forward clutch piston.
  
  Fig 18: Identifying O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 CLUTCH BALANCER
1. Coat a new O-ring with ATF and install it on the clutch balancer.
  
  Fig 19: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the No. 1 clutch balancer and forward clutch return spring sub-assembly.
  NOTE: Be careful not to damage the O-ring.
  
  Fig 20: Identifying No. 1 Clutch Balancer And Forward Clutch Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place SST on the No. 1 clutch balancer, and compress the return spring with a press.
  SST 09350-30020 (09350-07040, 09350-07070)
4. Install the snap ring with a snap ring expander.
5. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
  NOTE:
  - Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.
  - Do not expand the snap ring excessively.
    
    Fig 21: Installing No. 1 Clutch Balancer
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Set the end gap of the snap ring in the piston as shown in the illustration.
  
  Fig 22: Setting End Gap Of Snap Ring In Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FORWARD MULTIPLE DISC CLUTCH DISC
1. Install the 2 flanges, 6 discs and 5 plates to the input shaft assembly.
  Install in order: F-D-P-D-P-D-P-D-P-D-P-D-P-D-F
  
  HINT:
  
  P = Plate, D = Disc, F = Flange
  
  Fig 23: Identifying Flanges, Discs And Plates
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the hole snap ring.
  
  Fig 24: Installing Hole Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INPUT SHAFT OIL SEAL RING
1. Coat the 3 oil seal rings with ATF.
2. Squeeze the ends of the 3 oil seal rings together, and then install them to the starter shaft groove.
  NOTE: Do not over-spread the ring ends.
  
  HINT:
  
  After installing the oil seal rings, check that they rotate smoothly.
  
  Fig 25: Identifying Oil Seal Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PACK CLEARANCE OF FORWARD CLUTCH (See INSPECTION )

INSTALL INPUT SHAFT ASSEMBLY

Install the input shaft assembly to the clutch drum.

Fig 26: Identifying Input Shaft Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the thrust needle roller bearing to the clutch drum.

Standard thrust needle roller bearing diameter

THRUST NEEDLE ROLLER BEARING SPECIFICATION

Item	Inside	Outside
Thrust needle roller bearing	21.3 mm (0.839 in.)	41.1 mm (1.618 in.)

Fig 27: Identifying Thrust Needle Roller Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL MULTIPLE DISC CLUTCH HUB

install the No. 2 thrust bearing race and input shaft thrust bearing race rear to the multiple disc clutch hub.

Standard bearing and race diameter

BEARING AND RACE SPECIFICATION

Item	Inside	Outside
Thrust bearing race No. 2	38.4 mm (1.512 in.)	63.0 mm (2.480 in.)
Input shaft bearing race rear	22.6 mm (0.890 in.)	60.0 mm (2.362 in.)

Fig 28: Identifying No. 2 Thrust Bearing Race And Input Shaft Thrust Bearing Race Rear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the multiple disc clutch hub to the clutch drum.

Fig 29: Identifying Multiple Disc Clutch Hub
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY

Install the 2 thrust needle roller bearings to the forward clutch hub.

Standard bearing and race diameter

BEARING AND RACE SPECIFICATION

Item	Inside	Outside
Bearing A	42.5 mm (1.673 in.)	61.2 mm (2.409 in.)
Bearing B	33.3 mm (1.311 in.)	56.6 mm (2.228 in.)

Fig 30: Identifying Thrust Needle Roller Bearings

Install the forward clutch hub sub-assembly to the clutch drum.

Fig 31: Identifying Forward Clutch Hub Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR CLUTCH DISC
1. Install the clutch cushion plate, reverse clutch flange, 4 plates and 5 discs to the reverse clutch hub.
  Install in order: D-P-D-P-D-P-D-P-D-F
  
  HINT:
  
  P = Plate, D = Disc, F = Flange
  
  Fig 32: Identifying Clutch Cushion Plate, Reverse Clutch Flange, Plates And Discs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE CLUTCH REACTION SLEEVE
1. Install the reverse clutch reaction sleeve to the reverse clutch hub.
  
  Fig 33: Identifying Reverse Clutch Reaction Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY
1. Install the reverse clutch hub sub-assembly, reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates to the clutch drum.
  
  Fig 34: Identifying Reverse Clutch Hub Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the snap ring on the clutch drum and input shaft.
  
  Fig 35: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002