Intermediate Shaft: Disassembly

REMOVE REVERSE CLUTCH DISC
1. Using a screwdriver, remove the snap ring.
2. Remove the reverse clutch flange, 3 reverse clutch discs and 3 reverse clutch plates.
INSPECT REVERSE CLUTCH DISC (See REASSEMBLY )

Fig 1: Removing Reverse Clutch Flange, Reverse Clutch Discs And Reverse Clutch Plates
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIRECT CLUTCH DISC
1. Using a screwdriver, remove the snap ring.
2. Remove the 3 direct clutch plates, direct clutch flange and 3 direct clutch discs.
INSPECT DIRECT CLUTCH DISC (See REASSEMBLY )

Fig 2: Removing Direct Clutch Plates, Direct Clutch Flange And Direct Clutch Discs
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIRECT CLUTCH RETURN SPRING SUBASSEMBLY
1. Using SST and a press, remove the snap ring and direct clutch return spring sub-assembly from the intermediate shaft.
  SST 09387-00020
INSPECT DIRECT CLUTCH RETURN SPRING SUBASSEMBLY (See INSPECTION )

Fig 3: Removing Direct Clutch Return Spring Subassembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIRECT CLUTCH PISTON SUB-ASSEMBLY
1. Install the direct and reverse clutch on the transaxle rear cover.
2. Apply compressed air (392 kPa, 4.0 kgf*cm² , 57 psi) to the transaxle rear cover to remove the direct clutch drum and direct clutch piston sub-assembly.
  NOTE:
  - Blowing off the air may cause the piston to jump-out.
    When removing the piston, hold it with your hand using a waste cloth.
  - Take care not to splash ATF when airblowing.
  Fig 4: Installing Direct And Reverse Clutch On Transaxle Rear Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  When the piston cannot be removed as it is slanted, either blow the air again with the protruding side pushed or removed the piston using a needle nose pliers with vinyl tape on the tip.
INSPECT DIRECT CLUTCH PISTON SUB-ASSEMBLY (See INSPECTION )
REMOVE DIRECT CLUTCH DRUM SUB-ASSEMBLY
1. Align a matchmark on the direct clutch drum subassembly at the same position with the cutout of the intermediate shaft assembly.
2. Apply compressed air into the oil hole shown in the illustration and remove the direct clutch drum subassembly from the intermediate shaft.
INSPECT INTERMEDIATE SHAFT SUB-ASSEMBLY (See INSPECTION )

Fig 5: Applying Compressed Air Into Oil Hole
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIRECT CLUTCH PISTON O-RING
1. Using a screwdriver, remove the 2 direct clutch piston O-rings.
  
  Fig 6: Removing Direct Clutch Piston O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIRECT CLUTCH DRUM O-RING
1. Using a screwdriver, remove the direct clutch drum O-ring.
  
  Fig 7: Removing Direct Clutch Drum O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002