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Clutch Drum And Input Shaft Assembly: Reassembly

  1. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY 
    Fig 1: Identifying O-Rings & Direct Clutch Piston
    G04963726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat 2 new O-rings with ATF, and install them in the direct clutch piston.
      2. Fig 2: Identifying No. 2 Clutch Balancer & Direct Clutch Return Spring Sub-Assembly
      G04963725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 2 clutch balancer and direct clutch return spring to the direct clutch piston.
      3. Fig 3: Identifying O-Ring & Clutch Drum
      G04963724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat a new O-ring with ATF, and install them on the clutch drum sub-assembly.
    4. Be careful not to damage the O-rings. Press in the direct clutch piston into the clutch drum with both hands.
      5. Fig 4: Placing SST On Direct Clutch Piston & Compressing Return Spring With Press
      G04963722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Place SST on the direct clutch piston, and compress the return spring with a press.

      SST 09320-89010, 09350-30020 (09350-07070) 

    6. Install the snap ring with a snap ring expander.
      NOTE:
      • Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
      • Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.
      • Do not expand the snap ring excessively.
      7. Fig 5: Identifying End Gap Of Snap Ring In Piston
      G05261670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Set the end gap of the snap ring in the piston.
  2. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY 
    Fig 6: Identifying O-Ring & Clutch Drum
    G04963721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat a new O-ring with ATF, and install it on the clutch drum.
      2. Fig 7: Identifying O-Ring & Reverse Clutch Piston
      G04963720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat a new O-ring with ATF, and install it on the reverse clutch piston.
    3. Be careful not to damage the O-ring. Press in the clutch drum sub-assembly into the reverse clutch piston with both hands.
    Fig 8: Identifying Clutch Drum Sub-Assembly
    G05261673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Coat a new O-ring with ATF, and install it on the reverse clutch piston.
    2. Install the reverse clutch return spring onto the reverse clutch piston.
    Fig 9: Installing Reverse Clutch Return Spring
    G04963746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL NO. 3 CLUTCH BALANCER 
    Fig 10: Placing SST On No. 3 Clutch Balancer & Compressing Clutch Balancer With Press
    G04963717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Place SST on the No. 3 clutch balancer, and compress the clutch balancer with a press.

      SST 09387-00070, 09350-30020 (09350-07070) 

    2. Install the snap ring with a snap ring expander.
    3. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
      NOTE:
      • Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.
      • Do not expand the snap ring excessively.
      4. Fig 11: Identifying End Gap Of Snap Ring In Piston
      G04963748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Set the end gap of the snap ring in the piston.
  5. INSTALL DIRECT CLUTCH DISK 
    Fig 12: Identifying Reverse Clutch Flange, Plates & Discs
    G04963749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the reverse clutch flange, 6 plates and 5 discs on the clutch drum.

      Install in order: P - P - D - P - D - P - D - P - D - P - D - P - D - F 

      HINT:

      P = Plate, D = Disc, F = Flange

      2. Fig 13: Using Screwdriver To Install Hole Snap Rings
      G04963715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, install the 2 hole snap rings on the clutch drum.
  6. INSPECT PACK CLEARANCE OF DIRECT CLUTCH (See  INSPECTION   ) 
  7. INSTALL REVERSE CLUTCH FLANGE 
    1. Install the reverse clutch flange to the clutch drum.
      Fig 14: Identifying Reverse Clutch Flange & Clutch Drum
      G04963714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL REVERSE CLUTCH REACTION SLEEVE 
    Fig 15: Identifying Reverse Clutch Reaction Sleeve, Clutch Cushion Plate & Reverse Clutch Flange
    G04963752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates to the reverse clutch hub.
    2. Using a screwdriver, install the hole snap ring.
  9. INSPECT PACK CLEARANCE OF REVERSE CLUTCH (See  INSPECTION   ) 
  10. REMOVE REVERSE CLUTCH REACTION SLEEVE 
    Fig 16: Using Screwdriver To Remove Snap Ring
    G04963753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, remove the snap ring from the clutch drum.
      2. Fig 17: Identifying Reverse Clutch Reaction Sleeve, Clutch Cushion Plate & Reverse Clutch Flange
      G04963752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates from the reverse clutch hub.
  11. INSTALL FORWARD CLUTCH PISTON 
    Fig 18: Identifying O-Rings & No. 1 Forward Clutch Piston
    G04963713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat 2 new O-rings with ATF, and install them on the No. 1 forward clutch piston.
  12. INSTALL NO. 1 CLUTCH BALANCER 
    Fig 19: Identifying O-Ring & No. 1 Clutch Balancer
    G04963711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat a new O-ring with ATF and install it on the No. 1 clutch balancer.
      2. Fig 20: Identifying No. 1 Clutch Balancer & Forward Clutch Return Spring Sub-Assembly
      G05261685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 1 clutch balancer and forward clutch return spring sub-assembly.
      NOTE: Be careful not to damage the O-ring.
      3. Fig 21: Placing SST On No. 1 Clutch Balancer & Compressing Return Spring With Press
      G04963709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place SST on the No. 1 clutch balancer, and compress the return spring with a press.

      SST 09350-30020 (09350-07040, 09350-07070) 

    4. Install the snap ring with a snap ring expander.
    5. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
      NOTE:
      • Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.
      • Do not expand the snap ring excessively.
    6. Set the end gap of the snap ring in the piston.
      Fig 22: Identifying End Gap Of Snap Ring In Piston
      G04963759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC 
    Fig 23: Identifying Flanges, Discs & Plates
    G04963760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the 2 flanges, 6 discs and 5 plates to the input shaft assembly.

      Install in order: F - D - P - D - P - D - P - D - P - D - P - D - P - D - F 

      HINT:

      P = Plate, D = Disc, F = Flange

    2. Using a screwdriver, install the hole snap ring.
    Fig 24: Using Screwdriver To Install Hole Snap Ring
    G04963707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL INPUT SHAFT OIL SEAL RING 
    1. Coat the 3 oil seal rings with ATF.
      2. Fig 25: Identifying Oil Seal Rings
      G04963706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Squeeze the ends of the 3 oil seal rings together, and then install them to the starter shaft groove.
      NOTE: Do not over-spread the ring ends.

      HINT:

      After installing the oil seal rings, check that they rotate smoothly.

  15. INSPECT PACK CLEARANCE OF FORWARD CLUTCH (See  INSPECTION   ) 
  16. INSTALL INPUT SHAFT ASSEMBLY 
    Fig 26: Identifying Input Shaft Assembly & Clutch Drum
    G04963705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the input shaft assembly to the clutch drum.
      2. Fig 27: Identifying Thrust Needle Roller Bearing
      G04963704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the thrust needle roller bearing to the clutch drum.

    Standard thrust needle roller bearing diameter 

    STANDARD THRUST NEEDLE ROLLER BEARING DIAMETER

    Item Inside Outside
    Thrust needle roller bearing 21.3 mm (0.839 in.) 41.1 mm (1.618 in.)
  17. INSTALL MULTIPLE DISC CLUTCH HUB 
    Fig 28: Identifying No. 2 Thrust Bearing Race & Input Shaft Thrust Bearing Rear Race
    G05261693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the No. 2 thrust bearing race and input shaft thrust bearing rear race to the multiple disc clutch hub.

      Standard bearing and race diameter 

      STANDARD BEARING AND RACE DIAMETER

      Item Inside Outside
      No. 2 Thrust bearing race 38.4 mm (1.512 in.) 63.0 mm (2.480 in.)
      Input shaft bearing race rear 22.6 mm (0.890 in.) 60.0 mm (2.362 in.)
      2. Fig 29: Identifying Multiple Disc Clutch Hub
      G04963702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the multiple disc clutch hub to the clutch drum.
  18. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY 
    Fig 30: Identifying Thrust Needle Roller Bearings
    G04963767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the 2 thrust needle roller bearings to the forward clutch hub.

      Standard bearing and race diameter 

      STANDARD BEARING AND RACE DIAMETER

      Item Inside Outside
      Bearing A 42.5 mm (1.673 in.) 61.2 mm (2.409 in.)
      Bearing B 33.3 mm (1.311 in.) 56.6 mm (2.228 in.)
      2. Fig 31: Identifying Forward Clutch Hub Sub-Assembly & Clutch Drum
      G04963700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the forward clutch hub sub-assembly to the clutch drum.
  19. INSTALL REAR CLUTCH DISC 
    Fig 32: Identifying Clutch Cushion Plate, Reverse Clutch Flange, Plates & Discs
    G05197408Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the clutch cushion plate, reverse clutch flange, 4 plates and 5 discs to the reverse clutch hub.

      Install in order: D - P - D - P - D - P - D - P - D - F 

      HINT:

      P = Plate, D = Disc, F = Flange

  20. INSTALL REVERSE CLUTCH REACTION SLEEVE 
    1. Install the reverse clutch reaction sleeve to the reverse clutch hub.
    Fig 33: Identifying Reverse Clutch Reaction Sleeve & Reverse Clutch Hub
    G04963698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY 
      Fig 34: Identifying Reverse Clutch Hub Sub-Assembly & Reverse Clutch Reaction Sleeve
      G04963697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the reverse clutch hub sub-assembly, reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates to the clutch drum.
      2. Fig 35: Using Screwdriver To Install Snap Ring On Clutch Drum
      G04963696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, install the snap ring on the clutch drum and input shaft.
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