Toyota RAV4 manuals

Toyota RAV4 Service Manual: Direct clutch

Components

Toyota RAV4. Direct clutch


Disassembly

  1. Inspect pack clearance of direct clutch (see page ax-234)

  2. Remove direct multiple disc clutch disc

  1. Using a screwdriver, pry out the snap ring from the direct clutch drum.

Toyota RAV4. Remove direct multiple disc clutch disc


  1. Remove the flange, 3 discs and 3 plates from the direct clutch drum.

Toyota RAV4. Remove direct multiple disc clutch disc


  1. Inspect direct multiple disc clutch disc (see page ax-234)

  2. Remove direct clutch return spring subassembly

Toyota RAV4. Remove direct clutch return spring subassembly


  1. Place sst on the clutch balancer and compress the spring with a press.

Sst 09387-00020

  1. Using a snap ring expander, remove the snap ring from the direct clutch drum.

Notice:

Toyota RAV4. Remove direct clutch return spring subassembly


  1. Remove the clutch balancer from the direct clutch drum.

Toyota RAV4. Remove direct clutch return spring subassembly


  1. Remove the piston return spring from the direct clutch drum.

Toyota RAV4. Remove direct clutch return spring subassembly


  1. Install the direct clutch drum on the transaxle rear cover.
  2. Holding the direct clutch piston with your hand, apply compressed air (392 kpa, 4.0 Kgf*cm2, 57 psi) to the transaxle rear cover to remove the direct clutch piston.

Inspection

  1. Inspect pack clearance of direct clutch

Toyota RAV4. Inspect pack clearance of direct clutch


  1. Install the direct clutch and needle roller bearing on the transaxle rear cover.
  2. Using a dial indicator, measure the forward clutch pack clearance while applying and releasing compressed air (392 kpa, 4.0 Kgf/cm2, 57 psi)

Standard pack clearance: 0.515 To 0.825 Mm (0.0203 To 0.0324 In.)

If the pack clearance is not as specified, inspect the discs, plates and flange.

  1. Inspect direct multiple disc clutch disc

Toyota RAV4. Inspect direct multiple disc clutch disc


  1. Check to see if the sliding surface of the disc, plate and flange are worn or burnt.

    If necessary, replace them.

Hint:

  1. Inspect direct clutch return spring subassembly

Toyota RAV4. Inspect direct clutch return spring subassembly


  1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

    Standard free length: 22.58 Mm (0.8898 In.)

Reassembly

  1. Install direct clutch return spring subassembly

Toyota RAV4. Install direct clutch return spring subassembly


  1. Coat the direct clutch piston with atf, and install it to the direct clutch drum.

Notice:

Be careful not to damage the lip seal of the direct clutch piston.

Toyota RAV4. Install direct clutch return spring subassembly


  1. Install the piston return spring to the direct clutch drum.

Toyota RAV4. Install direct clutch return spring subassembly


  1. Install the clutch balancer to the direct clutch drum.

Notice:

Be careful not to damage the lip seal of the direct clutch balancer.

Toyota RAV4. Install direct clutch return spring subassembly


  1. Place sst on the clutch balancer and compress the piston return spring with a press.

Sst 09387-00020

  1. Using a snap ring expander, install the snap ring to the direct clutch drum.

Notice:

  1. Install direct multiple disc clutch disc

Toyota RAV4. Install direct multiple disc clutch disc


  1. Install the 3 plates, 3 discs and flange to the direct clutch drum.

Install in order: p - d - p - d - p - d - f

Hint:

P = plate

D = disc

F = flange

Toyota RAV4. Install direct multiple disc clutch disc


  1. Using a screwdriver, install the snap ring.
  2. Check that the end gap of the snap ring is not aligned with one of the cutouts.
  1. Inspect pack clearance of direct clutch

Toyota RAV4. Inspect pack clearance of direct clutch


  1. Install the direct clutch on the transaxle rear cover.
  2. Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (392 kpa, 4.0 Kgf/cm2, 57 psi).

Standard pack clearance: 0.515 To 0.825 Mm (0.0203 To 0.0324 In.)

If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble again.

If the stroke is not as specified, select another flange.

Hint:

There are 6 flanges in different thickness.

Standard flanges in different thickness


  1. Inspect direct multiple disc clutch disc

Toyota RAV4. Inspect direct multiple disc clutch disc


  1. Check that the disc rotates when rotating the disc after inserting the rear planetary sun gear.

Notice:

Do not place the rear planetary sun gear in a vise.

Forward clutch
Components Disassembly Inspect forward clutch (see page ax-227) Remove forward multiple disc clutch disc Using a screwdriver, remove the snap ring. Remove the flange , 5 discs a ...

Underdrive planetary gear
Components Disassembly Remove underdrive planetary gear preload (see page ax-240) Remove underdrive input shaft nut Sst 09930-00010 (09931-00010, 09931-00020), 09387-00050, 09564-1602 ...

Other materials:

Operation check
Check key reminder warning system Check that the key reminder warning buzzer sounds. With the driver side door closed, insert the key into the ignition key cylinder and then turn the ignition switch to lock or acc. Check that the buzzer sounds intermittently when the driver ...

Bleeding
Hint: If any work is performed on the brake system or if air in the brake lines is suspected, bleed air from the brake system. Notice: Wash off brake fluid immediately if it comes in contact with any painted surface. Remove cowl top ventilator louver bracket lh Detach the 6 claws and ...

If your vehicle has to be stopped in an emergency
Only in an emergency, such as if it becomes impossible to stop the vehicle in the normal way, stop the vehicle using the following procedure: Steadily step on the brake pedal with both feet and firmly depress it. Do not pump the brake pedal repeatedly as this will increase the effort req ...

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