Toyota RAV4 (XA40) 2013-2018 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:
Front passenger side - side airbag sensor assembly initialization incomplete
Description
The side airbag sensor rh consists of parts including the diagnostic circuit
and the lateral deceleration
sensor.
When the center airbag sensor receives signals from the lateral deceleration
sensor, it determines
whether or not the srs should be activated.
Dtc b1628/82, ...
On-vehicle inspection
Hint:
When pressing the switch for 0.3 Seconds or less, the roof
glass moves but auto operation does not operate.
Check auto operation
Turn the ignition switch on.
When the roof glass is fully closed, press the slide
open switch for 0.3 Seconds or more. Check that
the roof glass au ...
Mil circuit
Description
The mil (malfunction indicator lamp) is used to indicate vehicle malfunction
detections by the ecm.
When the ignition switch is turned on, power is supplied to the mil circuit, and
the ecm provides the
circuit ground which illuminates the mil.
The mil operation can be checked ...