Intermediate Shaft: Inspection

INSPECT REVERSE CLUTCH DISC
1. Check to see if the sliding surface of the disc, plate and flange are worn or burnt.
  If necessary, replace them.
  
  HINT:
  - If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs.
  - Before assembling new discs, soak them in ATF for at least 15 minutes.
    
    Fig 1: Inspecting Reverse Clutch Disc
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIRECT CLUTCH DISC
1. Check to see if the sliding surface of the disc, plate and flange are worn or burnt.
  If necessary, replace them.
  
  HINT:
  - If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs.
  - Before assembling new discs, soak them in ATF for at least 15 minutes.
    
    Fig 2: Inspecting Direct Clutch Disc
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIRECT CLUTCH RETURN SPRING SUBASSEMBLY
1. Using a vernier calipers, measure the free length of the spring together with the spring seat.
  Standard free length: 32.9 mm (1.2953 in.)
  
  Fig 3: Measuring Free Length Of Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIRECT CLUTCH PISTON SUB-ASSEMBLY
1. Shake the direct clutch pin and check that a check ball is not stuck.
2. Apply low pressure air to the check ball with compressed air and check for air leak.
  
  Fig 4: Applying Low Pressure Air To Check Ball With Compressed Air
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INTERMEDIATE SHAFT SUB-ASSEMBLY
1. Shake the direct clutch pin and check that a check ball is not stuck.
2. Apply low pressure air to the check ball with compressed air and check for air leak.
  
  Fig 5: Applying Low Pressure Air To Check Ball With Compressed Air
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PACK CLEARANCE OF REVERSE CLUTCH

Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover.

Using a dial indicator, measure the reverse clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf*cm² , 57 psi)

Pack clearance: 1.20 to 1.60 mm (0.0472 to 0.0630 in.)

If the pack clearance is less than the limit of pack clearance, parts may have been assembled incorrectly, so check and reassemble again. If the pack clearance is not standard value, choose another flange.

Fig 6: Measuring Reverse Clutch Pack Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

There are 4 flanges in different thickness.

Flange Thickness: mm (in.)

FLANGE THICKNESS SPECIFICATION (1 OF 2)

No.	Thickness	No.	Thickness
-	2.95 to 3.05 (0.116 to 0.120)	2	3.35 to 3.45 (0.132 to 0.136)
1	3.15 to 3.25 (0.124 to 0.128)	3	3.55 to 3.65 (0.140 to 0.144)

INSPECT PACK CLEARANCE OF DIRECT CLUTCH

Install the direct and reverse clutch and thrust needle roller bearing on the transaxle rear cover.

Using a dial indicator and measuring terminal (SST), measure the forward clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf*cm² , 57 psi)

SST 09350-36010 (09350-06110)

Fig 7: Measuring Forward Clutch Pack Clearance

HINT:

The direct and reverse clutch will come out when you apply the compressed air. Therefore, while the check is being performed, press on the input shaft of the direct and reverse clutch using stamping machine ore alike so that the pressure is not applied on the direct and reverse clutch.

Pack clearance: 0.62 to 1.02 mm (0.0244 to 0.0402 in.)

If the pack clearance is less than the limit of pack clearance, parts may have been assembled incorrectly, so check and reassembled again. If the pack clearance is not standard, choose another flange.

HINT:

There are 4 flanges in different thickness.

Selected flange thickness: mm (in.)

FLANGE THICKNESS SPECIFICATION (2 OF 2)

No.	Thickness	No.	Thickness
-	2.95 to 3.05 (0.116 to 0.120)	2	3.35 to 3.45 (0.132 to 0.136)
1	3.15 to 3.25 (0.124 to 0.128)	3	3.55 to 3.65 (0.140 to 0.144)