Toyota RAV4 Service Manual: Direct clutch
Components
Disassembly
- Inspect pack clearance of direct clutch
(see page ax-234)
- Remove direct multiple disc clutch disc
- Using a screwdriver, pry out the snap ring from the
direct clutch drum.
- Remove the flange, 3 discs and 3 plates from the
direct clutch drum.
- Inspect direct multiple disc clutch disc
(see page ax-234)
- Remove direct clutch return spring subassembly
- Place sst on the clutch balancer and compress the
spring with a press.
Sst 09387-00020
- Using a snap ring expander, remove the snap ring
from the direct clutch drum.
Notice:
- Stop the press when the spring sheet is
lowered to the place 1 to 2 mm (0.039 To 0.078
In.) From the snap ring groove.
- This prevents the spring sheet from being
deformed.
- Do not expand the snap ring excessively.
- Remove the clutch balancer from the direct clutch
drum.
- Remove the piston return spring from the direct
clutch drum.
- Install the direct clutch drum on the transaxle rear
cover.
- 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
- Inspect pack clearance of direct clutch
- Install the direct clutch and needle roller bearing on
the transaxle rear cover.
- 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.
- Inspect direct multiple disc clutch disc
- Check to see if the sliding surface of the disc, plate
and flange are worn or burnt.
If necessary, replace them.
Hint:
- If the lining of the disc is peeling off or discolored,
or even if a part of the printed mark is defaced,
replace all discs.
- Before assembling new discs, soak them in atf
for at least 15 minutes.
- Inspect direct clutch return spring subassembly
- 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
- Install direct clutch return spring subassembly
- 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.
- Install the piston return spring to the direct clutch
drum.
- Install the clutch balancer to the direct clutch drum.
Notice:
Be careful not to damage the lip seal of the
direct clutch balancer.
- Place sst on the clutch balancer and compress the
piston return spring with a press.
Sst 09387-00020
- Using a snap ring expander, install the snap ring to
the direct clutch drum.
Notice:
- Be sure the end gap of the snap ring is not
aligned with the clutch balancer claw.
- Stop the press when the spring sheet is
lowered to the place 1 to 2 mm (0.039 To 0.078
In.) From the snap ring groove.
- This prevents the spring sheet from being
deformed.
- Do not expand the snap ring excessively.
- Install direct multiple disc clutch disc
- 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
- Using a screwdriver, install the snap ring.
- Check that the end gap of the snap ring is not
aligned with one of the cutouts.
- Inspect pack clearance of direct clutch
- Install the direct clutch on the transaxle rear cover.
- 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
- Inspect direct multiple disc clutch disc
- 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.
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 ...
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:
Precaution
Tire pressure warning system precaution
When the tire pressure warning light turns on,
immediately check the tire pressure of the tire and
adjust it to the specified value. (When the tire
pressure warning light circuit is open, the tire
pressure warning light flashes for 1 minut ...
Headlight assembly
Components
Removal
Hint:
Use the same procedures for the rh and lh sides.
The procedures listed below are for the lh side.
Disconnect cable from negative battery
terminal
Remove front fender liner lh (see page et-4)
Remove front fender liner rh (see page et-4)
Remove ra ...
Curtain shield airbag assembly
Components
On-vehicle inspection
Check curtain shield airbag assembly (vehicle not involved in
collision)
Perform a diagnostic system check (see page rs-
49).
With the curtain shield airbag assembly installed on
the vehicle, perform a visual check. If any of the
defects ...