Intermediate Shaft: Reassembly

INSTALL DIRECT CLUTCH DRUM O-RING
1. Coat new direct clutch drum O-ring with ATF, install it to the direct clutch drum.
  NOTE: Be careful not to damage the O-ring.
  
  Fig 1: Installing Direct Clutch Drum O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT CLUTCH PISTON O-RING
1. Coat 2 new direct clutch piston O-rings with ATF, install them to the direct clutch piston.
  NOTE: Be careful not to damage the O-ring.
INSTALL DIRECT CLUTCH DRUM SUB-ASSEMBLY
1. Coat the direct clutch drum sub-assembly with ATF.
  
  Fig 2: Installing Direct Clutch Drum Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Aligning the cutout in the intermediate shaft assembly with the matchmark on the direct clutch drum, install the direct clutch drum sub-assembly to the intermediate shaft assembly.
  NOTE: Be careful not to damage the O-ring and clutch drum's lip.
  
  Fig 3: Aligning Cutout In Intermediate Shaft Assembly With Matchmark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY
1. Coat the direct clutch piston sub-assembly with ATF, install it to the intermediate shaft assembly.
  NOTE: Do not damage the O-ring on the direct clutch piston's.
  
  Fig 4: Installing Direct Clutch Piston Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT CLUTCH RETURN SPRING SUBASSEMBLY
1. Install the direct clutch return spring sub-assembly on the direct clutch piston sub-assembly.
2. Place SST on the piston return spring and compress the springs with a press.
  SST 09387-00020
3. Using a snap ring expander, install the snap ring in the direct clutch drum.
  
  Fig 5: Placing SST On Piston Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Stop the press when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, preventing the spring sheet from the deforming.
  - Do not expand the snap ring excessively.
INSTALL DIRECT CLUTCH DISC
1. Coat the 3 direct clutch plates, 3 direct clutch discs and direct clutch flange with ATF, install them to the intermediate shaft assembly.
2. Install the snap ring.
  
  Fig 6: Installing Direct Clutch Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REVERSE CLUTCH DISC
1. Install the 3 reverse clutch plates, 3 reverse clutch discs and a reverse clutch flange.
2. Install the snap ring.
INSPECT PACK CLEARANCE OF REVERSE CLUTCH (See INSPECTION )
INSPECT PACK CLEARANCE OF DIRECT CLUTCH (See INSPECTION )

Fig 7: Installing Reverse Clutch Plates
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002