Direct Clutch: Reassembly

INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY
1. Coat the 2 new O-rings with ATF and install 2 new O-rings to the direct clutch piston sub-assembly.
2. Being careful not to damage the O-rings, press the direct clutch piston sub-assembly into the drum with the cup side up.
  
  Fig 1: Installing Direct Clutch Piston Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Install the direct clutch return spring sub-assembly to the direct clutch drum sub-assembly.
  
  Fig 2: Installing Direct Clutch Return Spring Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT CLUTCH PISTON RETURN SPRING SHAFT SNAP RING
1. Place SST on the direct clutch return spring sub-assembly, and compress the direct clutch return spring sub-assembly with a press.
  SST 09350-32014 (09351-32070)
2. Using snap ring pliers, install the direct clutch piston return spring shaft snap ring to the direct clutch drum sub- assembly.
  HINT:
  
  Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
  
  Fig 3: Installing Direct Clutch Piston Return Spring Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT MULTIPLE DISC CLUTCH, CLUTCH DISC
1. Install the 3 clutch plates and 3 direct multiple disc clutch, clutch disc in order.
  Install in order:
  
  P - Plate D = Disc F = Flange P - D - P - D - P - D - F
2. Install the clutch flange with the flat side facing downward.
  
  Fig 4: Installing Clutch Flange With Flat Side Facing Downward
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT CLUTCH FLANGE HOLE SNAP RING
1. Using a screwdriver, install the direct clutch flange hole snap ring to the direct clutch drum sub-assembly.
2. Check that the end gap of the direct clutch flange hole snap ring is not aligned with one of the cutouts.
  
  Fig 5: Installing Direct Clutch Flange Hole Snap Ring To Direct Clutch Drum Subassembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL PACK CLEARANCE OF DIRECT CLUTCH

Install the direct clutch onto the oil pump.

Fig 6: Installing Direct Clutch On Oil Pump
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Set a dial indicator and measuring terminal (SST) together, and measure the direct clutch pack clearance while applying and releasing compressed air (392 to 785 kPa, 4 to 8 kgf/² , 57 to 114 psi).

SST 09350-32014 (09351-32190)

Pack clearance:

0.49 to 0.89 mm (0.0192 to 0.0350 in.)

If the pack clearance is non-standard, select another flange.

HINT:

There are 4 different thickness for the flange.

Flange thickness: mm (In.)

THICKNESS CHART

thickness	thickness
2.60 (0.1024)	3.00 (0.1181)
2.80 (0.1102)	3.20 (0.1260)

Fig 7: Measuring Clutch Clearance