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 Direct Clutch Piston O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the No. 2 clutch balancer and direct clutch return spring to the direct clutch piston.
3. Press the direct clutch piston into the clutch drum by hand.
  NOTE: Do not damage the O-rings.
  
  Fig 2: Identifying No. 2 Clutch Balancer 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
5. Using SST, install the snap ring.
  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 seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent spring seat deformation.
  - 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: Setting End Gap Of Snap Ring
  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 clutch drum.
  
  Fig 5: Identifying Reverse Clutch Piston O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat a new O-ring with ATF, and install it on the reverse clutch piston.
  
  Fig 6: Identifying Reverse Clutch Piston O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Press the clutch drum 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.
  
  Fig 7: Identifying Reverse Clutch Piston And Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the reverse clutch return spring onto the reverse clutch piston.
  
  Fig 8: Identifying Reverse Clutch Return Spring And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 3 CLUTCH BALANCER
1. Install the clutch balancer to the reverse clutch return spring.
2. Place SST on the clutch balancer, and compress the clutch balancer with a press.
  SST 09387-00070
3. Using SST, install the snap ring.
  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 spring sheet deformation.
  - Do not expand the snap ring excessively.
    
    Fig 9: Installing Snap Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Set the end gap of the snap ring in the piston as shown in the illustration.
  
  Fig 10: Setting End Gap Of Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT CLUTCH DISC
1. Install the 6 plates, 5 discs and flange on the clutch drum.
  Install in order:
  
  P - P - D - P - D - P - D - P - D - P - D - F
  
  HINT:
  
  P = Plate
  
  D = Disc
  
  F = Flange
  
  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 clutch drum.
INSPECT PACK CLEARANCE OF DIRECT CLUTCH (See INSPECTION )

Fig 12: Installing Hole Snap Rings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE CLUTCH FLANGE
1. Install the flange to the clutch drum.
  
  Fig 13: Identifying Reverse Clutch Flange
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE CLUTCH REACTION SLEEVE
1. Install the 5 discs, 4 plates, flange, cushion plate and sleeve to the reverse clutch hub.
  Install in order:
  
  D - P - D - P - D - P - D - P - D - F - C - S
  
  HINT:
  
  D = Disc
  
  P = Plate
  
  F = Flange
  
  C = Cushion Plate
  
  S = Sleeve
2. Using a screwdriver, install the hole snap ring.
INSPECT PACK CLEARANCE OF REVERSE CLUTCH (See INSPECTION )

Fig 14: Identifying Installation Order Of Reverse Clutch Reaction Sleeve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE CLUTCH REACTION SLEEVE
1. Using a screwdriver, remove the snap ring from the clutch drum.
  
  Fig 15: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the sleeve, cushion plate, flange, 5 discs, and 4 plates from the reverse clutch hub.
  
  Fig 16: Identifying Reverse Clutch Reaction Sleeve And Clutch Cushion Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY
1. Install the coast clutch piston to the forward clutch piston.
2. Install the O-ring to the forward clutch.
3. Install the forward clutch piston to the input shaft.
  
  Fig 17: Identifying Coast Clutch Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 CLUTCH BALANCER
1. Coat a new O-ring with ATF and install it on the clutch balancer.
  
  Fig 18: Identifying Clutch Balancer O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the clutch balancer and forward clutch return spring.
  NOTE: Do not damage the O-ring.
  
  Fig 19: Identifying Clutch Balancer And Forward Clutch Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place SST on the clutch balancer, and compress the return spring with a press.
  SST 09350-30020 (09350-07040)
4. Using SST, install the snap ring.
  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 spring sheet deformation.
  - Do not expand the snap ring excessively.
    
    Fig 20: Installing Snap Ring
    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: Setting End Gap Of Snap Ring In Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COAST CLUTCH DISC
1. Install the 3 plates, 3 discs and flange to the forward clutch piston.
  Install in order:
  
  P - D - P - D - P - D - F
  
  HINT:
  
  P = Plate
  
  D = Disc
  
  F = Flange
2. Using a screwdriver, install the hole snap ring.
  
  Fig 22: Identifying Plates, Discs And Flange
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PACK CLEARANCE OF COAST CLUTCH (See INSPECTION )

INSTALL FORWARD CLUTCH HUB CLUTCH DISC

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

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

HINT:

C = Cushion Plate

P = Plate

D = Disc

F = Flange

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

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

Install the thrust needle roller bearing and thrust bearing race.

Standard bearing and race diameter

BEARING AND RACE DIAMETER SPECIFICATION

Item	Inside	Outside
Thrust needle roller bearing	21.3 mm (0.839 in.)	41.1 mm (1.618 in.)
No. 2 thrust bearing race	22.6 mm (0.890 in.)	44.8 mm (1.764 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, and then install them to the input 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 Input Shaft Oil Seal Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PACK CLEARANCE OF FORWARD CLUTCH (See INSPECTION )

INSTALL INPUT SHAFT ASSEMBLY

Install the input shaft to the clutch drum.

Fig 27: Identifying Input Shaft And Clutch Drum
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the thrust needle roller bearing to the clutch drum.

Standard thrust needle roller bearing diameter

THRUST NEEDLE ROLLER BEARING DIAMETER SPECIFICATION

Item	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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL COAST CLUTCH HUB SUB-ASSEMBLY

Install the underdrive 1-way clutch, clutch hub thrust washer and input shaft rear thrust bearing race to the coast clutch hub.

Standard bearing race diameter

BEARING RACE DIAMETER SPECIFICATION

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

Fig 29: Identifying Thrust Washer And Thrust Bearing Race

Install the coast clutch hub to the clutch drum.

Fig 30: Identifying Coast Clutch Hub
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY

Install the 2 thrust needle roller bearings and No. 3 thrust bearing race to the forward clutch hub.

Standard bearing and race diameter

BEARING RACE DIAMETER SPECIFICATION

Item	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.)
No. 3 thrust bearing race	35.6 mm (1.402 in.)	56.6 mm (2.228 in.)

Fig 31: Identifying Thrust Needle Roller Bearings And Thrust Bearing Race

Install the clutch hub thrust washer and forward clutch hub to the clutch drum.

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

INSTALL REAR CLUTCH DISC
1. Install the 5 discs, 4 plates, flange and cushion plate to the reverse clutch hub.
  Install in order:
  
  D - P - D - P - D - P - D - P - D - F - C
  
  HINT
  
  D = Disc
  
  P = Plate
  
  F = Flange
  
  C = Cushion plate
  
  Fig 33: Identifying Discs, Plates, Flange And 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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY
1. Install the reverse clutch hub, reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and clutch plates to the clutch drum.
  
  Fig 35: Identifying Reverse Clutch Hub Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the snap ring on the clutch drum and input shaft.
  
  Fig 36: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002