Forward Clutch: Reassembly

INSTALL INPUT SHAFT OIL SEAL RING
1. Compress a new input shaft oil seal ring from both sides to reduce dimension A.
  Dimension A:
  
  5 mm (0.197 in.)
2. Coat the oil seal ring with ATF and install it to the input shaft.
  NOTE: Do not expand the end gap of the oil seal ring too much. Fix the hooks firmly.
  
  Fig 1: Compressing Input Shaft Oil Seal Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY
1. Coat the forward clutch piston with ATF and install it to the input shaft.
  NOTE: Be careful not to damage the lip of the forward clutch piston.
  
  Fig 2: Installing Forward Clutch Piston Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Install the return spring to the input shaft.
  NOTE: After installing the spring sub-assembly, check that all of the springs are engaged in the piston correctly.
2. Coat the clutch balancer with ATF.
  
  Fig 3: Identifying Forward Clutch Return Spring And Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the clutch balancer to the input shaft.
  NOTE:
  - Be careful not to damage the lip of the forward clutch balancer.
  - Make sure that the clutch balancer is not pinched and that there are no other defects on the lip.
  - Apply sufficient ATF to the sealing lip before installation.
    
    Fig 4: Identifying Clutch Balancer And Input Shaft
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place SST on the clutch balancer, and compress the clutch balancer with a press.
  SST 09387-00020
5. Install the snap ring with a snap ring expander.
6. Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
  NOTE:
  - Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove. This prevents the spring seat from being deformed.
  - Do not expand the snap ring excessively.
    
    Fig 5: Removing Snap Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Set the end gap of the snap ring in the piston as shown in the illustration.
  NOTE: The end gap of the snap ring should not align with any of the stoppers.
  
  Fig 6: Identifying Stoppers Location
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FORWARD MULTIPLE DISC CLUTCH DISC
1. Coat the 5 discs with ATF.
2. Install the 5 plates, 5 discs, and flange input shaft.
  NOTE: Make sure that the plates, discs, and flange are installed as shown in the illustration.
  
  Fig 7: Identifying Plates, Discs And Flange
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, install the snap ring.
4. Check that the end gap of the snap ring is not aligned with one of the cutouts.
  NOTE: The snap ring should be fully engaged in the groove of the drum.
  
  Fig 8: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PACK CLEARANCE OF FORWARD CLUTCH (See INSPECTION )
INSPECT FORWARD MULTIPLE DISC CLUTCH DISC (See INSPECTION )