Direct Clutch: Disassembly

INSPECT PACK CLEARANCE OF REVERSE CLUTCH
HINT:

(See INSPECTION )
INSPECT PACK CLEARANCE OF DIRECT CLUTCH AND OVERDRIVE CLUTCH
HINT:

(See INSPECTION )
REMOVE DIRECT MULTIPLE DISC CLUTCH
1. Using a screwdriver, remove the snap ring from the intermediate shaft.
  
  Fig 1: Removing Snap Ring From Intermediate Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the flange, 3 discs, 3 plates and cushion plate from the intermediate shaft.
  
  Fig 2: Removing Flange, Discs, Plates And Cushion Plate From Intermediate Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OVERDRIVE DIRECT CLUTCH DISC
1. Using a screwdriver, remove the snap ring from the intermediate shaft.
2. Remove the flange, 4 discs and 4 plates from the intermediate shaft.
  
  Fig 3: Removing Flange, Discs And Plates From Intermediate Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OVERDRIVE 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.
  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.
    
    Fig 4: Removing Snap Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - This prevents the spring seat from being deformed.
  - Do not expand the snap ring excessively.
3. Remove the clutch balancer from the direct clutch drum.
  
  Fig 5: Identifying Clutch Balancer And Direct Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the overdrive clutch return spring from the direct clutch drum.
  
  Fig 6: Identifying Overdrive Clutch Return Spring And Direct Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OVERDRIVE DIRECT CLUTCH PISTON
1. Install the intermediate shaft on the transaxle rear cover.
2. Holding the direct clutch piston with your hand, apply compressed air (392 kPa, 4.0 kgf/cm² , 57 psi) to the transaxle rear cover to remove the direct clutch piston.
  
  Fig 7: Removing Overdrive Direct Clutch Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY
1. Holding the direct clutch drum by hand, apply compressed air (392 kPa, 4.0 kgf/cm² , 57 psi) to the transaxle rear cover to remove the direct clutch drum.
  
  Fig 8: Removing Overdrive Direct Clutch Drum Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OVERDRIVE DIRECT CLUTCH O-RING
1. Using a screwdriver, remove the O-ring from the direct clutch drum.
  
  Fig 9: Locating Overdrive Direct Clutch O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002