Clutch Drum And Input Shaft Assembly: Inspection

INSPECT UNDERDRIVE 1-way CLUTCH ASSEMBLY
1. Hold the coast clutch hub and turn the 1-way clutch.
2. Check that the 1-way clutch turns freely counterclockwise and locks clockwise.
  If there is a problem with the 1-way clutch, replace it.
  
  Fig 1: Checking 1-way Clutch Turn Freely
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Using a vernier caliper, measure the free length of the spring together with the spring seat.
  Standard free length: 19.51 mm (0.768 in.)
  
  If the free length is not as specified, replace the clutch return spring sub-assembly.
  
  Fig 2: Measuring Free Length Of Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Using a vernier caliper, measure the free length of the spring together with the spring seat.
  Standard free length: 21.04 mm (0.828 in.)
  
  If the free length is not as specified, replace the clutch return spring sub-assembly.
  
  Fig 3: Measuring Free Length Of Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIRECT CLUTCH DISC
1. Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage.
  NOTE: Before assembling new discs, soak them in ATF for at least 15 minutes.
  
  Fig 4: Inspecting No. 3 Brake Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PACK CLEARANCE OF DIRECT CLUTCH

Inspect the pack clearance of the direct clutch.

Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across the diameter while blowing air into the oil hole as shown in the illustration, and calculate the average.
HINT:

Flange moving distance A = 0.26 to 1.14 mm (0.010 to 0.045 in.)

Pack clearance = Flange moving distance A - 0.05 mm (0.002 in.)

Standard pack clearance: 0.5 to 0.8 mm (0.020 to 0.031 in.)

NOTE: When measuring the moving distance, install a standard flange (thickness: 3.4 mm, 0.134 in.) to the position of the shaded area shown in the illustration.

Fig 5: Measuring Reverse Clutch Piston Stroke And Moving Distance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the pack clearance is not as specified, select and install a clutch flange that brings the pack clearance within the standard.

HINT:

There are 9 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

Flange thickness

THICKNESS REFERENCE CHART

No.	Thickness
0	3.0 mm (0.118 in.)
1	3.1 mm (0.122 in.)
2	3.2 mm (0.126 in.)
3	3.3 mm (0.130 in.)
4	3.4 mm (0.134 in.)
5	3.5 mm (0.138 in.)
6	3.6 mm (0.142 in.)
7	3.7 mm (0.146 in.)
8	3.8 mm (0.150 in.)

INSPECT PACK CLEARANCE OF REVERSE CLUTCH

Inspect the pack clearance of the reverse clutch hub.

Using a dial indicator, measure the reverse clutch piston stroke (distance A) and moving distance (distance B) of the reverse clutch flange at both ends across the diameter while blowing air (392 kPa, 4 kgf/cm² , 57 psi) into the oil hole as shown in the illustration, and calculate the average.

Fig 6: Measuring Reverse Clutch Piston Stroke And Moving Distance Of Reverse Flange
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Piston stroke A = 1.05 to 2.15 mm (0.041 to 0.085 in.)

Flange moving distance B = 0.72 to 1.08 mm (0.028 to 0.043 in.)

Pack clearance = Piston stroke A - Flange moving distance B - 0.06 mm (0.002 in.)

Standard pack clearance: 0.5 to 0.8 mm (0.020 to 0.031 in.)

NOTE: When measuring the moving distance, install a standard flange (thickness: 3.3 mm, 0.130 in.) to the position of the shaded area shown in the illustration.

If the pack clearance is outside the standard, select and install a clutch flange that brings the pack clearance within the standard.

HINT:

There are 11 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

Standard flange thickness

THICKNESS REFERENCE CHART

No.	Thickness
0	2.8 mm (0.110 in.)
1	2.9 mm (0.114 in.)
2	3.0 mm (0.118 in.)
3	3.1 mm (0.122 in.)
4	3.2 mm (0.126 in.)
5	3.3 mm (0.130 in.)
6	3.4 mm (0.134 in.)
7	3.5 mm (0.138 in.)
8	3.6 mm (0.142 in.)
9	3.7 mm (0.146 in.)
A	3.8 mm (0.150 in.)

INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Using a vernier caliper, measure the free length of the spring together with the spring seat.
  Standard free length: 24.64 mm (0.9701 in.)
  
  If the free length is not as specified, replace the clutch return spring sub-assembly.
  
  Fig 7: Measuring Free Length Of Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT COAST CLUTCH DISC
1. Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage.
  NOTE: Before assembling new discs, soak them in ATF for at least 15 minutes.
  
  Fig 8: Inspecting No. 3 Brake Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PACK CLEARANCE OF COAST CLUTCH

Inspect the pack clearance of the coast clutch hub.

Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across the diameter while blowing air into the oil hole as shown in the illustration, and calculate the average.
HINT:

Flange moving distance A = 0.38 to 1.48 mm (0.01496 to 0.0583 in.)

Pack clearance = Flange moving distance A - 0.02 mm (0.0008 in.)

Standard pack clearance: 0.3 to 0.6 mm (0.012 to 0.024 in.)

NOTE: When measuring the moving distance, install a standard flange (thickness: 3.0 mm, 0.018 in.) to the position of the shaded area shown in the illustration.

Fig 9: Measuring Moving Distance Of Clutch Flange
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the pack clearance is not as specified, select and install a clutch flange that brings the pack clearance within the standard.

HINT:

There are 10 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

Standard flange thickness

THICKNESS REFERENCE CHART

No.	Thickness
0	3.0 mm (0.118 in.)
1	3.1 mm (0.122 in.)
2	3.2 mm (0.126 in.)
3	3.3 mm (0.130 in.)
4	3.4 mm (0.134 in.)
5	3.5 mm (0.138 in.)
6	3.6 mm (0.142 in.)
7	3.7 mm (0.146 in.)
8	3.8 mm (0.150 In.)
9	3.9 mm (0.154 in.)

INSPECT FORWARD CLUTCH HUB CLUTCH DISC
1. Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage.
  NOTE: Before assembling new discs, soak them in ATF for at least 15 minutes.
  
  Fig 10: Inspecting No. 3 Brake Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PACK CLEARANCE OF FORWARD CLUTCH

Inspect the pack clearance of the forward clutch.

Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across the diameter while blowing air into the oil hole as shown in the illustration, and calculate the average.
HINT:

Flange moving distance A = 0.36 to 1.50 mm (0.142 to 0.0591 in.)

Pack clearance = Flange moving distance A - 0.11 mm (0.0043 in.)

Standard pack clearance: 0.56 to 0.86 mm (0.0220 to 0.0339 in.)

NOTE: When measuring the moving distance, install a standard flange (thickness: 3.4 mm, 0.134 in.) to the position of the shaded area shown in the illustration.

Fig 11: Measuring Moving Distance (Distance A) Of Clutch Flange
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the pack clearance is not as specified, select and install a clutch flange that brings the pack clearance within the standard.

HINT:

There are 11 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

Standard flange thickness

THICKNESS REFERENCE CHART

No.	Thickness
0	3.0 mm (0.118 in.)
1	3.1 mm (0.122 in.)
2	3.2 mm (0.126 in.)
3	3.3 mm (0.130 in.)
4	3.4 mm (0.134 in.)
5	3.5 mm (0.138 in.)
6	3.6 mm (0.142 in.)
7	3.7 mm (0.146 in.)
8	3.8 mm (0.150 in.)
9	3.9 mm (0.154 in.)
A	4.0 mm (0.158 in.)

INSPECT FORWARD CLUTCH HUB SUB-ASSEMBLY
1. Using a caliper gauge, measure the inside diameter of the forward clutch hub bush.
  Standard inside diameter: 26.037 to 26.062 mm (1.0251 to 1.0261 in.)
  
  If the inside diameter is not as specified, replace the forward clutch hub sub-assembly.
  
  Fig 12: Measuring Inside Diameter Of Forward Clutch Hub Bush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REAR CLUTCH DISC
1. Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage.
  NOTE: Before assembling new discs, soak them in ATF for at least 15 minutes.
  
  Fig 13: Inspecting No. 3 Brake Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY
1. Using a caliper gauge, measure the inside diameter of the reverse clutch hub bush.
  Standard inside diameter: 35.812 to 35.837 mm (1.4099 to 1.4109 in.)
  
  If the inside diameter is not as specified, replace the reverse clutch hub sub-assembly.
  
  Fig 14: Measuring Inside Diameter Of Reverse Clutch Hub Bush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002