Direct Clutch: Reassembly

INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY
1. Coat the 2 new O-rings with ATF and install 2 new O-rings to the direct clutch piston sub-assembly.
2. Being careful not to damage the O-rings, press the direct clutch piston sub-assembly into the drum with the cup side up.
  
  Fig 1: Identifying Direct Clutch Piston Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Install the direct clutch return spring sub-assembly to the direct clutch drum sub-assembly.
  
  Fig 2: Identifying Direct Clutch Return Spreing Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT CLUTCH PISTON RETURN SPRING SHAFT SNAP RING
1. Place SST on the direct clutch return spring sub-assembly, and compress the direct clutch return spring sub-assembly with a press.
  SST 09350-32014 (09351 -32070)
2. Using snap ring pliers, install the direct clutch piston return spring shaft snap ring to the direct clutch drum sub- assembly.
  HINT:
  
  Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
  
  Fig 3: Identifying Direct Clutch Piston Return Spring Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT MULTIPLE DISC CLUTCH CLUTCH DISC
1. Install the 3 clutch plates and 3 direct multiple disc clutch clutch disc in order.
  Install in order:
  
  P = Plate D = Disc F = Flange P - D - P - D - P - D - F
  
  Fig 4: Identifying Clutch Plates And Direct Multiple Disc Clutch Clutch Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the clutch flange with the flat side facing downward.
INSTALL DIRECT CLUTCH FLANGE HOLE SNAP RING
1. Using a screwdriver, install the direct clutch flange hole snap ring to the direct clutch drum sub-assembly.
2. Check that the end gap of the direct clutch flange hole snap ring is not aligned with one of the cutouts.

INSTALL PACK CLEARANCE OF DIRECT CLUTCH

Install the direct clutch onto the oil pump.

Fig 6: Identifying Dial Indicator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Set a dial indicator and measuring terminal (SST) together, and measure the direct clutch pack clearance while applying and releasing compressed air (392 to 785 kPa, 4 to 8 kgf/cm² , 57 to 114 psi).

SST 09350-32014 (09351 -32190)

Pack clearance:

0.49 to 0.89 mm (0.0192 to 0.0350 in.)

If the pack clearance is non-standard, select another flange.

HINT:

There are 4 different thickness for the flange.

Fig 7: Identifying Pack Clearance Of Direct Clutch

Flange thickness: mm (in.)

FLANGE THICKNESS SPECIFICATION

thickness	thickness
2.60 (0.1024)	3.00 (0.1181)
2.80 (0.1102)	3.20 (0.1260)