Intermediate Shaft: Reassembly

INSTALL DIRECT CLUTCH DRUM O-RING
1. Coat a new O-ring with ATF and install it to the direct clutch drum.
  NOTE: Do not damage the O-ring.
  
  Fig 1: Locating Direct Clutch Drum O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT CLUTCH PISTON O-RING
1. Coat 2 new O-rings with ATF and install them to the direct clutch piston.
  NOTE: Do not damage the O-rings.
  
  Fig 2: Locating Direct Clutch Piston O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT CLUTCH DRUM SUB-ASSEMBLY
1. Coat the direct clutch drum with ATF.
2. Align a cutout on the intermediate shaft assembly with the matchmark on the direct clutch drum and install the direct clutch drum to the intermediate shaft assembly.
  NOTE: Do not damage the O-ring or the lip of the clutch drum.
  
  Fig 3: Aligning Cutout On Intermediate Shaft Assembly With Matchmark On Direct Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY
1. Coat the direct clutch piston with ATF and install it to the intermediate shaft.
  NOTE: Do not damage the O-ring or the direct clutch piston.
  
  Fig 4: Identifying Direct Clutch Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Install the direct clutch return spring onto the direct clutch piston.
2. Place SST on the piston return spring and compress the springs with a press.
  SST 09387-00020
3. Using snap ring pliers, install the snap ring to the direct clutch drum.
  
  Fig 5: Installing Snap Ring To Direct Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Stop pressing the press when the spring seat is lowered to 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring seat from deforming.
  - Do not expand the snap ring excessively.
INSTALL DIRECT CLUTCH DISC
1. Coat the 3 rear clutch flanges, 3 discs and direct clutch flange with ATF and install them to the intermediate shaft.
2. Install the snap ring to the intermediate shaft.
INSTALL REVERSE CLUTCH DISC
1. Coat the 3 plates, 3 discs and flange with ATF, and install them to the intermediate shaft.
2. Install the snap ring to the intermediate shaft.

INSPECT PACK CLEARANCE OF REVERSE CLUTCH

Install the intermediate shaft and thrust needle roller bearing to the transaxle rear cover.

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:

0.862 to 1.262 mm (0.339 to 0.0497 in.)

Fig 8: Measuring Pack Clearance Of Reverse Clutch

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: If the clearance is not within the specified range, select a new clutch flange.

HINT:

There are 4 different flange thicknesses.

Flange thickness

FLANGE THICKNESS SPECIFICATION

No.	Thickness mm (in.)	No.	Thickness mm (in.)
-	3.0 (0.118)	2	3.4 (0.134)
1	3.2 (0.126)	3	3.6 (0.142)

INSPECT PACK CLEARANCE OF DIRECT CLUTCH

Install the intermediate shaft and thrust needle roller bearing to the transaxle rear cover.

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

SST 09350-36010 (09350-06110)

HINT:

The direct and reverse clutch will come out as the compressed air is applied.

Fig 9: Measuring Pack Clearance Of Direct Clutch

Therefore, while performing the check, press on the input shaft of the direct and reverse clutch using a press or the equivalent so that the pressure is not applied to the direct and reverse clutch.

Pack clearance:

0.62 to 1.02 mm (0.0244 to 0.0402 in.)

NOTE: If the clearance is not within the specified range, select a new clutch flange.

HINT:

There are 4 different flange thicknesses.

Flange thickness

FLANGE THICKNESS SPECIFICATION

No.	Thickness mm (in.)	No.	Thickness mm (in.)
-	3.0 (0.118)	2	3.4 (0.134)
1	3.2 (0.126)	3	3.6 (0.142)