Direct Clutch: Reassembly

INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY
1. Coat the 2 new O-rings with ATF and install 2 new O-rings to the direct clutch piston sub-assembly.
2. Being careful not to damage the O-rings, press the direct clutch piston sub-assembly into the drum with the cup side up.
  
  Fig 1: Installing Direct Clutch Piston Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT CLUTCH RETURN SPRING SUBASSEMBLY
1. Install the direct clutch return spring sub-assembly to the direct clutch drum sub-assembly.
  
  Fig 2: Installing Direct Clutch Return Spring Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT CLUTCH PISTON RETURN SPRING SHAFT SNAP RING
1. Place SST on the direct clutch return spring subassembly, and compress the direct clutch return spring sub-assembly with a press.
  SST 09350-32014 (09351-32070)
2. Using snap ring pliers, install the direct clutch piston return spring shaft snap ring to the direct clutch drum sub- assembly.
  HINT:
  
  Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
  
  Fig 3: Installing Direct Clutch Piston Return Spring Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT MULTIPLE DISC CLUTCH DISC
1. Install the 3 clutch plates and 3 direct multiple disc clutch disc in order.
  Install in order: P = Plate D = Disc F = Flange P - D - P - D - P - D - F
2. Install the clutch flange with the flat side facing downward.
  
  Fig 4: Installing Clutch Flange With Flat Side Facing Downward
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT CLUTCH FLANGE HOLE SNAP RING
1. Using a screwdriver, install the direct clutch flange hole snap ring to the direct clutch drum subassembly.
2. Check that the end gap of the direct clutch flange hole snap ring is not aligned with one of the cutouts.
  
  Fig 5: Installing Direct Clutch Flange Hole Snap Ring To Direct Clutch Drum Subassembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL PACK CLEARANCE OF DIRECT CLUTCH

Install the direct clutch onto the oil pump.

Fig 6: Installing Direct Clutch Onto Oil Pump
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Set a dial indicator and measuring terminal (SST) together, and measure the direct clutch pack clearance while applying and releasing compressed air (392 to 785 kPa, 4 to 8 kgf/cm² , 57 to 114 psi).

SST 09350-32014 (09351-32190)

Pack clearance: 0.49 to 0.89 mm (0.0192 to 0.0350 in.)

If the pack clearance is non-standard, select another flange.

HINT:

There are 4 different thickness for the flange.

Flange thickness: mm (in.)

Fig 7: Measuring Clutch Clearance

FLANGE THICKNESS

thickness	thickness
2.60 (0.1024)	3.00 (0.1181)
2.80 (0.1102)	3.20 (0.1260)