Direct Clutch: Reassembly

INSTALL OVERDRIVE DIRECT CLUTCH O-RING
1. Coat a new O-ring with ATF and install to the direct clutch drum.
  NOTE: Make sure that the O-ring is not twisted or pinched when it is installed.
  
  Fig 1: Locating O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY
1. Coat the direct clutch drum with ATF and install it to the intermediate shaft.
  NOTE:
  - Be careful not to damage the O-ring.
  - Be careful not to damage the lip of the direct clutch drum.
    
    Fig 2: Identifying Direct Clutch Drum And Intermediate Shaft
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OVERDRIVE DIRECT CLUTCH PISTON
1. Coat the overdrive direct clutch piston with ATF, and install it to the direct clutch drum.
  
  Fig 3: Identifying Overdrive Direct Clutch Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Install the overdrive clutch return spring to the direct clutch drum.
  NOTE: After installing the spring sub-assembly, check that all of the springs are engaged in the piston correctly.
2. Coat the clutch balancer with ATF.
  
  Fig 4: Identifying Overdrive Clutch Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the clutch balancer to the direct clutch drum.
  NOTE:
  - Be careful not to damage the lip of the direct clutch balancer.
  - Make sure that the lip of the seal is not pinched and that it has no other defects.
  - Apply sufficient ATF to the sealing lip before installing the clutch balancer.
    
    Fig 5: Identifying Clutch Balancer And Direct Clutch Drum
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place SST on the clutch balancer and compress the overdrive clutch return spring with a press.
  SST 09387-00020
5. Using a snap ring expander, install the snap ring to the direct clutch drum.
6. Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
  
  Fig 6: Compressing Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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. This prevents the spring seat from being deformed.
  - Do not expand the snap ring excessively.
7. Set the end gap of the snap ring in the piston as shown in the illustration.
  NOTE: The end gap of the snap ring should not align with any of the stoppers.
  
  Fig 7: Identifying Stoppers Location
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OVERDRIVE DIRECT CLUTCH DISC
1. Coat the 4 discs with ATF.
2. Install the 4 plates, 4 discs, and flange to the intermediate shaft.
  NOTE: Make sure that the plates, discs, and flange are installed as shown in the illustration.
  
  Fig 8: Identifying Plates, Discs And Flange
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, install the snap ring.
4. Check that the end gap of the snap ring is not aligned with one of the cutouts.
  NOTE: The snap ring should be fully engaged in the groove of the drum.
  
  Fig 9: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT MULTIPLE DISC CLUTCH
1. Coat the 3 discs with ATF.
2. Install the cushion plate, 3 plates, 3 discs, and flange to the intermediate shaft.
  NOTE:
  - Install the cushion plate with the mark on the white surface facing to plate.
  - Make sure that the discs, plates, and flange are installed in the correct order.
    
    Fig 10: Identifying Cushion Plate, Plates, Disc And Flange
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, install the snap ring.
4. Check that the end gap of the snap ring is not aligned with one of the cutouts.
  NOTE: The snap ring should be fully engaged in the groove of the drum.
  
  Fig 11: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002