Direct Clutch: Inspection

INSPECT PACK CLEARANCE OF REVERSE CLUTCH
1. Install the intermediate shaft and needle roller bearing onto the transaxle rear cover.
2. 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:
  
  0.60 to 0.82 mm (0.0236 to 0.0323 in.)
  
  If the pack clearance is not as specified, inspect the discs, plates, and flange.
  
  Fig 1: Measuring Reverse Clutch Pack Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PACK CLEARANCE OF DIRECT CLUTCH AND OVERDRIVE CLUTCH
1. Using a dial indicator, measure the direct clutch and overdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm² , 57 psi).
  Pack clearance:
  
  0.61 to 0.83 mm (0.0240 to 0.0327 in.)
  
  If the pack clearance is not as specified, inspect the discs, plates, and flange.
  
  Fig 2: Measuring Direct Clutch And Overdrive Clutch Pack Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIRECT MULTIPLE DISC CLUTCH DISC
1. Check if the sliding surfaces of the disc, plate, and flange are worn or burnt. If necessary, replace them.
  HINT:
  - If the lining of the disc comes off or discolors, or if a part of the groove is worn, replace all discs.
  - Before installing new discs, immerse them in ATF for at least 15 minutes.
    
    Fig 3: Identifying Direct Multiple Disc Clutch Disc
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT OVERDRIVE DIRECT CLUTCH DISC
1. Check 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 comes off or discolors, or if a part of the groove is worn, replace all discs.
  - Before installing new discs, immerse them in ATF for at least 15 minutes.
    
    Fig 4: Identifying Overdrive Direct Clutch Disc
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Using vernier calipers, measure the free length of the spring together with the spring seat.
  Standard free length:
  
  25.91 mm (1.0201 in.)
  
  If the result is not as specified, replace the spring.
  
  Fig 5: Measuring Free Length Of Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PACK CLEARANCE OF REVERSE CLUTCH

Install the intermediate shaft onto the transaxle rear cover.

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

Clearance:

0.60 to 0.82 mm (0.0236 to 0.0323 in.)

If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble again. If the clearance is not as specified, select another flange.

HINT:

There are 7 different thicknesses of flanges available.

Fig 6: Measuring Direct Clutch Pack Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Flange thickness: mm (in.)

FLANGE THICKNESS SPECIFICATION

No.	Thickness	No.	Thickness
1	3.0 (0.118)	5	3.4 (0.134)
2	3.1 (0.122)	6	3.5 (0.138)
3	3.2 (0.126)	7	3.6 (0.142)
4	3.3 (0.130)	-	-

INSPECT PACK CLEARANCE OF DIRECT CLUTCH AND OVERDRIVE CLUTCH

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