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Intermediate Shaft: Reassembly: Reassembly

  1. INSTALL DIRECT CLUTCH DRUM O-RING 
    1. Coat a new O-ring with Toyota Genuine ATF WS or equivalent and install it to the direct clutch drum.
      Fig 1: Identifying Direct Clutch Drum O-Ring
      GTY166822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not damage the O-ring.

  2. INSTALL DIRECT CLUTCH PISTON O-RING 
    1. Coat 2 new O-rings with Toyota Genuine ATF WS or equivalent and install them to the direct clutch piston.
      Fig 2: Identifying Direct Clutch Piston O-Rings
      GTY159432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not damage the O-rings.

  3. INSTALL DIRECT CLUTCH DRUM SUB-ASSEMBLY 
    1. Coat the direct clutch drum with Toyota Genuine ATF WS or equivalent.
    2. Align a cutout on the intermediate shaft assembly with the matchmark on the direct clutch drum and install the direct clutch drum to the intermediate shaft assembly.
      Fig 3: Aligning Cutout On Intermediate Shaft Assembly With Matchmark On Direct Clutch Drum
      GTY157696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not damage the O-ring or the lip of the clutch drum.

  4. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY 
    1. Coat the direct clutch piston with Toyota Genuine ATF WS or equivalent and install it to the intermediate shaft.
      Fig 4: Identifying Direct Clutch Piston
      GTY165337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not damage the O-ring or the direct clutch piston.

  5. INSTALL DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Install the direct clutch return spring onto the direct clutch piston.
      Fig 5: Installing Direct Clutch Return Spring Snap Ring Using SST
      GTY159430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place SST on the piston return spring and compress the springs with a press.
      • SST: 09387-00020 
    3. Using snap ring pliers, install the snap ring to the direct clutch drum.
      NOTE:
      • Stop pressing the press when the spring seat is lowered to 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring seat from deforming.
      • Do not expand the snap ring excessively.
  6. INSTALL DIRECT CLUTCH DISC 
    1. Coat the 3 rear clutch flanges, 3 discs and direct clutch flange with Toyota Genuine ATF WS or equivalent and install them to the intermediate shaft.
      Fig 6: Identifying Rear Clutch Flanges, Discs & Direct Clutch Flange
      GTY157697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the snap ring to the intermediate shaft.
  7. INSTALL REVERSE CLUTCH DISC 
    1. Coat the 3 plates, 3 discs and flange with Toyota Genuine ATF WS or equivalent, and install them to the intermediate shaft.
      Fig 7: Identifying Plates, Discs & Flange
      GTY166032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the snap ring to the intermediate shaft.
  8. INSPECT PACK CLEARANCE OF REVERSE CLUTCH 
    1. Install the intermediate shaft and thrust needle roller bearing to the transaxle rear cover.
      Fig 8: Measuring Pack Clearance Of Reverse Clutch Using Dial Indicator
      GTY158070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a dial indicator, measure the reverse clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi).

      Pack clearance

      0.862 to 1.262 mm (0.339 to 0.0497 in.)

      NOTE:

      If the clearance is not within the specified range, select a new clutch flange.

      HINT: 

      There are 4 different flange thicknesses.

      Flange thickness

      No. Thickness mm (in.) No. Thickness mm (in.)
      - 3.0 (0.118) 2 3.4 (0.134)
      1 3.2 (0.126) 3 3.6 (0.142)
  9. INSPECT PACK CLEARANCE OF DIRECT CLUTCH 
    1. Install the intermediate shaft and thrust needle roller bearing to the transaxle rear cover.
      Fig 9: Measuring Pack Clearance Of Direct Clutch Using Dial Indicator
      GTY158071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a dial indicator and measuring terminal (SST), measure the forward clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi).
      • SST: 09350-36010 
        • 09350-06110

      HINT: 

      The direct and reverse clutch will come out as the compressed air is applied.

      Therefore, while performing the check, press on the input shaft of the direct and reverse clutch using a press or the equivalent so that the pressure is not applied to the direct and reverse clutch.

      Pack clearance

      0.62 to 1.02 mm (0.0244 to 0.0402 in.)

      NOTE:

      If the clearance is not within the specified range, select a new clutch flange.

      HINT: 

      There are 4 different flange thicknesses.

      Flange thickness

      No. Thickness mm (in.) No. Thickness mm (in.)
      - 3.0 (0.118) 2 3.4 (0.134)
      1 3.2 (0.126) 3 3.6 (0.142)
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