Toyota RAV4 Service Manual: Underdrive clutch
Components

Disassembly
- Inspect pack clearance of underdrive
clutch (see page ax-247)
- Remove no. 1 Underdrive clutch disc

- Using a screwdriver, pry out the underdrive clutch
flange snap ring.
- Remove the flange, 3 discs and 3 plates from the
underdrive clutch drum.
- Inspect no. 1 Underdrive clutch disc (see page
ax-248)

- Inspect underdrive clutch drum subassembly
(see page ax-248)
- Remove underdrive clutch drum o-ring

- Remove underdrive clutch piston set

- Place sst on the clutch balancer and compress the
spring with a press.
Sst 09350-32014 (09351-32070)
- Using a snap ring expander, remove the snap ring.
Notice:
- Stop the press when the spring sheet is
lowered to a position 1 to 2 mm (0.04 To 0.08
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 underdrive
clutch drum.

- Remove the piston return spring from the
underdrive clutch drum.

- Install the underdrive clutch to the transaxle.
Notice:
Be careful not to damage the oil seal rings.
- Holding the underdrive clutch piston with your hand,
apply compressed air (392 kpa, 4.0 Kgf/cm2, 57 psi)
to the transaxle case to remove the underdrive
clutch piston.
- Inspect underdrive clutch return spring
sub-assembly (see page ax-248)

Inspection
- Inspect underdrive clutch pack clearance

- Install the underdrive clutch to the transaxle.
Notice:
Be careful not to damage the oil seal rings.
- Install a dial indicator as shown in the illustration.
- Measure the underdrive clutch pack clearance while
applying and releasing compressed air (392 kpa, 4.0Kgf/cm2,
57 psi)

Standard pack clearance:
1.51 To 1.90 Mm (0.0594 To 0.0748 In.)
If the pack clearance is not as specified, inspect the
discs, plates and flange.
- Inspect no. 1 Underdrive 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 discs 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 underdrive clutch drum subassembly

- Using a caliper gauge measure the inside diameter
of the underdrive clutch drum bush.
Standard drum bush:
37.06 To 37.08 Mm (1.4591 To 1.4598 In.)
Maximum drum bush:
37.13 Mm (1.4618 In.)
If the inside diameter is greater then the maximum,
replace the underdrive clutch drum sub-assembly.
- Inspect underdrive clutch return spring
sub-assembly

- Using a vernier caliper, measure the free length of
the spring together with the spring seat.
Standard free length:
17.14 Mm (0.6752 In.)
Installation
- Install underdrive clutch piston set

- Coat the underdrive clutch piston with atf, and
install it to the underdrive clutch piston drum.
Notice:
Be careful not to damage the o-ring.

- Install the piston return spring to the underdrive
clutch drum.

- Install the clutch balancer to the underdrive clutch
drum.
Notice:
Be careful not to damage the lip seal of the
clutch balancer.

- Place sst on the clutch balancer and compress the
piston return spring with a press.
Sst 09350-32014 (09351-32070)
- Using a snap ring expander, install the snap ring to
the underdrive clutch drum.
Notice:
- Be sure the end gap of the snap ring is not
aligned with the clutch balancer's claw.
- Stop the press when the spring sheet is
lowered to a position 1 to 2 mm (0.039 0.078
In.) From the snap ring groove.
- This prevents the spring sheet from being
deformed.
- Do not expand the snap ring excessively.

- Set the end gap of the snap ring in the underdrive
clutch drum shown in the illustration.
Notice:
The end gap of the snap ring should not
coincide with any of the stopper.
- Install underdrive clutch drum o-ring

- Coat the new o-ring with atf, and install it to the
underdrive clutch drum.
- Install no. 1 Underdrive clutch disc

- Install the 3 plates, 3 discs and flange to the
underdrive clutch drum.
Install in order:
p - d - p - d - p - d - f
Hint:
P = plate
D = disc
F = flange

- Using a screwdriver, install the underdrive clutch
flange hole snap ring.
- Check that the end gap of the snap ring is not
aligned with one of the cutouts.
- Inspect underdrive clutch pack clearance

- Install the underdrive clutch to the transaxle.
Notice:
Be careful not to damage the oil seal rings.
- Set a dial indicator as shown in the illustration.

- Measure the underdrive clutch piston stroke while
applying and releasing compressed air (392 kpa,
4.0 Kgf/cm2, 57 psi).
Standard pack clearance:
1.51 To 1.90 Mm (0.0594 To 0.0748 In.)
If the pack clearance is less than the minimum,
parts may have been assembled incorrectly, so
check and reassemble again.
If the park clearance is not as specified, select
another flange.
Hint:
There are 3 flanges in different thickness.
Standard flange thickness

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 ...
Components
Disassembly
Remove shift solenoid valve slt
Remove the bolt, plate and shift solenoid valve slt
from the valve body.
Remove shift solenoid valve sl1
Rem ...
Other materials:
Oxygen (a/f) sensor heater control circuit
Hint:
Although the dtc titles say oxygen sensor, these dtcs relate to the
air-fuel ratio (a/f) sensor.
Sensor 1 refers to the sensor mounted in front of the three-way
catalytic converter (twc) and
located near the engine assembly.
Description
Refer to dtc p2195 (see page es-292 ...
Throttle actuator control system
Description
The throttle actuator is operated by the ecm, and opens and closes the
throttle valve using gears. The
opening angle of the throttle valve is detected by the throttle position (tp)
sensor, which is mounted on
the throttle body. The tp sensor provides feedback to the ecm in ord ...
General driving notes
Closing the trunk lid
Safety information
Warning
An open trunk lid protrudes from the vehicle
and can endanger occupants and other traffic
participants or damage the vehicle in the event
of an accident, braking or evasive maneuvers.
In addition, exhaust fumes may enter the car's
interior. The ...