Clutch Drum And Input Shaft Assembly: Reassembly

INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY
1. Coat 2 new O-rings with ATF, and install them in the direct clutch piston.
  
  Fig 1: Identifying O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the No. 2 clutch balancer and the direct clutch return spring to the direct clutch piston sub-assembly.
3. Press the direct clutch piston into the reverse clutch drum sub-assembly by hands.
  NOTE: Do not damage the 2 O-rings.
  
  Fig 2: Identifying Clutch Balancer No 2 And Direct Clutch Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place SST on the direct clutch piston, and compress the return spring with a press.
  SST 09320-89010, 09350-30020 (09350-07070)
5. Install the snap ring with a snap ring expander.
  NOTE:
  - Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
  - Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.
  - Do not expand the snap ring excessively.
    
    Fig 3: Installing Snap Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Set the end gap of the snap ring in the piston as shown in the illustration.
  
  Fig 4: Identifying End Gap Of Snap Ring In Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY
1. Coat a new O-ring with ATF, and install it on the reverse clutch drum sub-assembly.
  
  Fig 5: Identifying O-Ring With ATF
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat a new O-ring with ATF, and install it on the reverse clutch piston sub-assembly.
  
  Fig 6: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Press the reverse clutch drum sub-assembly into the reverse clutch piston with both hands.
  NOTE: Do not damage the O-ring.
INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Coat a new O-ring with ATF, and install it on the reverse clutch piston sub-assembly.
  
  Fig 7: Identifying Reverse Clutch Drum Sub-Assembly Into Reverse Clutch Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the reverse clutch return spring onto the reverse clutch piston sub-assembly.
  
  Fig 8: Identifying O-Ring On Reverse Clutch Piston Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 3 CLUTCH BALANCER
1. install the No. 3 clutch balancer to the reverse clutch return spring.
2. Place SST on the No. 3 clutch balancer, and compress the clutch balancer with a press.
  SST 09387-00050,09387-00070
3. Install the snap ring with a snap ring expander.
  SST 09350-30020 (09350-07070)
  NOTE:
  - Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
  - Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.
    
    Fig 9: Installing Snap Ring Using SST
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Do not expand the snap ring excessively.
4. Set the end gap of the snap ring in the piston as shown in the illustration.
  
  Fig 10: Identifying Gap Of Snap Ring In Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 DIRECT CLUTCH DISC
1. Install the reverse clutch flange, the 6 plates and the 5 discs on the reverse clutch drum sub-assembly.
  Install in order:
  
  P = Plate, D = Disc, F = Flange, F - D - P - D - P - D - P - D - P - D - P - P
  
  Fig 11: Identifying Reverse Clutch Flange, Plates And Discs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the 2 hole snap rings on the reverse clutch drum sub-assembly.
  
  Fig 12: Identifying Hole Snap Rings On Clutch Drum Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PACK CLEARANCE OF DIRECT CLUTCH (See INSPECTION )
INSTALL REVERSE CLUTCH FLANGE
1. Install the reverse clutch flange to the reverse clutch drum sub-assembly.
  
  Fig 13: Identifying Reverse Clutch Flange To Reverse Clutch Drum Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE CLUTCH REACTION SLEEVE
1. Install the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 5 reverse clutch discs, and the 4 clutch plates to the reverse clutch hub.
  
  Fig 14: Identifying Reverse Clutch Reaction Sleeve, Clutch Cushion Plate And Reverse Clutch Flange
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Install in order:
  
  P = Plate, D = Disc, F = Flange, S = Sleeve, C = Cushion Plate
  
  S - C - F - D - P - D - P - D - P - D - P - D
2. Using a screwdriver, install the hole snap ring.
INSPECT PACK CLEARANCE OF REVERSE CLUTCH (See INSPECTION )
REMOVE REVERSE CLUTCH REACTION SLEEVE
1. Using a screwdriver, remove the snap ring from the reverse clutch drum sub-assembly.
  
  Fig 15: Removing Snap Ring From Clutch Drum Assembly Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 5 reverse clutch discs, and the 4 clutch plates from the reverse clutch hub sub-assembly.
  
  Fig 16: Identifying Reverse Clutch Discs And Clutch Plates From Reverse Clutch Hub Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY
1. Install the coast clutch piston to the input shaft.
2. Install a new O-ring to the forward clutch.
3. Install the forward clutch piston sub-assembly to the input shaft.
  
  Fig 17: Identifying Coast Clutch Piston To Forward Clutch Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 CLUTCH BALANCER
1. Coat a new D-ring with ATF and install it on the No. 1 clutch balancer.
  
  Fig 18: Identifying D-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the No. 1 clutch balancer and the forward clutch return spring sub-assembly.
  NOTE: Do not damage the D-ring.
  
  Fig 19: Identifying Clutch Balancer No 1 And Forward Clutch Return Spring Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place SST on the No. 1 clutch balancer, and compress the return spring with a press.
  SST 09350-30020 (09350-07040, 09350-07070)
4. Install the snap ring with a snap ring expander.
  NOTE:
  - Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
  - Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.
  - Do not expand the snap ring excessively.
    
    Fig 20: Compressing Return Spring Using SST
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Set the end gap of the snap ring in the piston as shown in the illustration.
  
  Fig 21: Identifying End Gap Of Snap Ring In Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COAST CLUTCH DISC
1. Install the flange, the 3 discs and the 3 plates to the forward clutch piston.
  
  Fig 22: Identifying Flange, Discs And Plates To Forward Clutch Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the hole snap ring.
INSPECT PACK CLEARANCE OF COAST CLUTCH (See INSPECTION )

INSTALL NO. 1 CLUTCH DISC

Install the flange, the 4 discs, the 4 plates and clutch cushion plate to the input shaft assembly.
Install in order:

P = Plate, D = Disc, F = Flange, C = Cushion Plate

F - D - P - D - P - D - P - D - P - C

Fig 23: Identifying Flange, Discs, Plates And Clutch Cushion Plate To Input Shaft Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a screwdriver, install the hole snap ring.

Fig 24: Installing Hole Snap Ring Using Screwdriver
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the thrust needle roller bearing and the thrust bearing race.

THRUST NEEDLE ROLLER BEARING

	Inside	Outside
Thrust needle roller bearing	34.6 mm (1.362 in.)	52.0 mm (2.047 in.)
Thrust bearing race	37.0 mm (1.457 in.)	52.3 mm (2.059 in.)

Fig 25: Identifying Thrust Needle Roller Bearing And Thrust Bearing Race

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL INPUT SHAFT OIL SEAL RING
1. Coat 4 new oil seal rings with ATF.
2. Squeeze the ends of the 4 oil seal rings together, and then install them to the starter shaft groove.
  NOTE: Do not expand the ring ends excessively.
  
  HINT:
  
  After installing the oil seal rings, check that they rotate smoothly.
  
  Fig 26: Identifying Oil Seal Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PACK CLEARANCE OF FORWARD CLUTCH (See INSPECTION )

INSTALL INPUT SHAFT

Install the input shaft to the reverse clutch drum sub-assembly.

Fig 27: Identifying Input Shaft To Reverse Clutch Drum Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the thrust needle roller bearing to the reverse clutch drum sub-assembly.

Thrust needle roller bearing diameter

THRUST NEEDLE ROLLER BEARING DIAMETER

	Inside	Outside
Thrust needle roller bearing	21.3 mm (0.839 in.)	41.1 mm (1.618 in.)

Fig 28: Identifying Thrust Needle Roller Bearing To Clutch Drum

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL COAST CLUTCH HUB SUB-ASSEMBLY

Install the underdrive one way clutch, clutch hub thrust washer and the input shaft rear thrust bearing race to the coast clutch hub.

Bearing and race diameter

BEARING AND RACE DIAMETER

	Inside	Outside
Input shaft rear thrust bearing race	22.6 mm (0.890 in.)	44.8 mm (1.764 in.)

Fig 29: Identifying Thrust Bearing Washer And Bearing Race

Install the coast clutch hub sub-assembly to the reverse clutch drum sub-assembly.

Fig 30: Identifying Coast Clutch Hub Sub-Assembly To Clutch Drum
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL CLUTCH HUB SUB-ASSEMBLY

Install the 2 thrust needle roller bearings to the clutch hub sub-assembly.

Bearing and race diameter

BEARING AND RACE DIAMETER

	Inside	Outside
Bearing A	42.5 mm (1.673 in.)	61.2 mm (2.409 in.)
Bearing B	35.6 mm (1.402 in.)	56.6 mm (2.228 in.)

Fig 31: Identifying Thrust Needle Roller Bearings

Install the clutch hub thrust washer and forward clutch hub sub-assembly to the reverse clutch drum sub-assembly.

Fig 32: Identifying Clutch Hub Thrust Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL NO. 3 CLUTCH DISC
1. Install the clutch cushion plate, the reverse clutch flange, the 4 plates and the 5 discs to the reverse clutch hub,
  
  Fig 33: Identifying Clutch Cushion Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE CLUTCH REACTION SLEEVE
1. Install the reverse clutch reaction sleeve to the reverse clutch hub.
  
  Fig 34: Identifying Reverse Clutch Reaction Sleeve To Reverse Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY
1. Install the reverse clutch hub sub-assembly, the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 5 reverse clutch discs, and the clutch plates to the reverse clutch drum sub-assembly.
  
  Fig 35: Identifying Reverse Clutch Hub Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the snap ring on the reverse clutch drum sub-assembly and the input shaft assembly.
  
  Fig 36: Identifying Snap Ring On Clutch Drum And Input Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002