Direct Clutch: Reassembly

INSTALL DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Coat the direct clutch piston with ATF, and install it onto the direct clutch drum.
  NOTE: Be careful not to damage the lip seal of the direct clutch piston.
  
  Fig 1: Installing Direct Clutch Return Spring Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the piston return spring onto the direct clutch drum.
  
  Fig 2: Installing Piston Return Spring Onto Direct Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the clutch balancer onto the direct clutch drum.
  NOTE: Be careful not to damage the lip seal of the direct clutch balancer.
  
  Fig 3: Installing Clutch Balancer Onto Direct Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place SST on the clutch balancer and compress the piston return spring with a press.
  SST 09387-00020
5. Using a snap ring expander, install the snap ring into the direct clutch drum.
  
  Fig 4: Installing Snap Ring Into Direct Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be sure the end gap of the snap ring is not aligned with the clutch balancer 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 snap ring groove.
  - This prevents the spring sheet from being deformed.
  - Do not expand the snap ring excessively.
INSTALL DIRECT MULTIPLE DISC 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 on the snap ring is not aligned with one of the cutouts.
  
  Fig 6: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PACK CLEARANCE OF DIRECT CLUTCH

Install the direct clutch on the transaxle rear cover.

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 less than the minimum, parts may have been assembled incorrectly, so check and reassemble again.

If the stroke is not as specified, select another flange.

Fig 7: Measuring Direct Clutch Pack Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

There are 6 flanges in different thickness.

Standard flange thickness

STANDARD FLANGE THICKNESS

Mark	Thickness	Mark	Thickness
0	2.9 mm (0.114 in.)	4	3.3 mm (0.130 in.)
1	3.0 mm (0.118 in.)	5	3.4 mm (0.134 in.)
2	3.1 mm (0.122 in.)	6	3.5 mm (0.138 in.)
3	3.2 mm (0.126 in.)	7	3.6 mm (0.142 in.)

INSPECT DIRECT MULTIPLE DISC CLUTCH DISC
1. Inspect the clutch disc rotation.
  1. Check that the disc rotates when rotating the disc after inserting the rear planetary sun gear.
    NOTE: Do not place the rear planetary sun gear in a vise.
    
    Fig 8: Inspecting Direct Multiple Disc Clutch Disc
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002