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Intermediate Shaft: Disassembly

  1. REMOVE REVERSE CLUTCH DISC 
    1. Using a screwdriver, remove the snap ring.
      2. Fig 1: Removing Snap Ring
      G04831500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, 3 discs and 3 plates.
  2. REMOVE DIRECT CLUTCH DISC 
    1. Using a screwdriver, remove the snap ring.
      2. Fig 2: Removing Snap Ring
      G04831501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the direct clutch flange, 3 direct clutch discs and 3 rear clutch flanges.
  3. REMOVE DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Using SST and a press, remove the snap ring.

      SST 09387-00020 

      Fig 3: Removing Snap Ring
      G04831502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the direct clutch return spring sub-assembly from the intermediate shaft.
  4. REMOVE DIRECT CLUTCH PISTON SUB-ASSEMBLY 
    1. Install the intermediate shaft onto the transaxle rear cover.
    2. Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the oil hole shown in the illustration and remove the direct clutch piston from the intermediate shaft.
      NOTE:
      • Blowing the air may cause the piston to jump out. When removing the piston, hold it by hand using a or piece of cloth.
      • Do not splash ATF with the compressed air.
        Fig 4: Removing Direct Clutch Piston From Intermediate Shaft
        G04831503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE DIRECT CLUTCH DRUM SUB-ASSEMBLY 
    1. Install the intermediate shaft onto the transaxle rear cover.
    2. Put a matchmark on the direct clutch drum in the same position as the cutout of the intermediate shaft assembly.
      Fig 5: Removing Direct Clutch Drum
      G04831504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the oil hole shown in the illustration and remove the direct clutch drum from the intermediate shaft.
      NOTE:
      • Blowing the air may cause the drum to jump out. When removing the drum, hold it by hand using a shop rag or piece of cloth.
      • Do not splash ATF with the compressed air.
  6. REMOVE DIRECT CLUTCH PISTON O-RING 
    1. Using a screwdriver, remove the 2 piston O-rings from the direct clutch piston.
      Fig 6: Locating Direct Clutch Piston O-Rings
      G05400342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE DIRECT CLUTCH DRUM O-RING 
    1. Using a screwdriver, remove the direct clutch drum O-ring from the direct clutch drum.
      Fig 7: Locating Direct Clutch Drum O-Ring
      G05400343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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