Direct Clutch: Disassembly

INSPECT PACK CLEARANCE OF DIRECT CLUTCH
1. Install the direct clutch and needle roller bearing on the transaxle rear cover.
2. Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm² , 57 psi).
  Standard pack clearance:
  
  0.652 to 0.872 mm (0.0257 to 0.0343 in.)
  
  If the pack clearance is not as specified, inspect the discs, plates and flange.
  
  Fig 1: Measuring Direct Clutch Pack Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIRECT MULTIPLE DISC CLUTCH DISC
1. Using a screwdriver, pry the snap ring out from the direct clutch drum.
  
  Fig 2: Prying Snap Ring Out From Direct Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the flange, 3 discs and 3 plates from the direct clutch drum.
  
  Fig 3: Identifying Flange, Discs And Plates
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY
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.
  
  Fig 4: Removing Snap Ring From Direct Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - 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.
3. Remove the clutch balancer from the direct clutch drum.
  
  Fig 5: Removing Clutch Balancer From Direct Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the piston return spring from the direct clutch drum.
  
  Fig 6: Removing Piston Return Spring From Direct Clutch Drum
  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 oil hole and remove the direct clutch piston.
  NOTE:
  - Applying the air may cause the piston to jump out. When removing the piston, hold it using a piece of cloth.
  - Do not splash ATF with the compressed air.
  Fig 7: Applying Compressed Air To Oil Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002