Operation CHARM: Car repair manuals for everyone.
Hosted by mcallihan.com
Home >> Toyota >> 2001 >> Echo L4-1.5L (1NZ-FE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Service and Repair >> Disassembly/Inspection/Reassembly of Components >> Direct and Reverse Clutch

Direct and Reverse Clutch

Direct and Reverse Clutch:






DISASSEMBLY





1. REMOVE SNAP RING
Using a screwdriver, remove the snap ring.





2. REMOVE FLANGE, DISC AND PLATE
a. U340E:
Remove the flange, 2 discs and 2 plates.
b. U341E:
Remove the flange, 3 discs and 3 plates.





3. REMOVE SNAP RING
Using a screwdriver, remove the snap ring.





4. REMOVE FLANGE, DISC AND PLATE
Remove the flange, 3 discs and 3 plates.





5. REMOVE PISTON RETURN SPRING
a. Place SST on the piston return spring and compress the springs with a press.
SST 09387-00020
b. Using a snap ring expander, remove the snap ring from the direct clutch drum.

NOTICE:
- Stop the press when the spring shoot is lowered to the place 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove, preventing the spring sheet from the deforming.
- Do not expand the snap ring excessively.

c. Remove the piston return spring.





6. REMOVE DIRECT CLUTCH DRUM AND DIRECT CLUTCH PISTON
a. Install the direct and reverse clutch on the transaxle rear cover.
b. Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle rear cover to remove the direct clutch drum and direct clutch piston.

NOTICE:
- Blowing of the air may cause the piston to jump-out. When removing the piston, hold it with your hand using a waste cloth.
- Take care not to splash ATF when air-blowing.

HINT: When the piston can not be removed as it is slanted, either blow the air again with the protruding side pushed or remove the piston using a needle nose pliers with vinyl tape on the tip.





7. REMOVE O-RING
Using a screwdriver, remove the O-rings from the direct clutch drum and direct clutch piston.

INSPECTION





1. INSPECT DISC AND FLANGE
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 number is defaced, replace all discs.
- Before assembling new discs, soak them in ATF for at least 15 minutes.





2. CHECK DIRECT CLUTCH RETURN SPRING
Using a vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 32.9 mm (1.2953 inch)

REASSEMBLY





1. INSTALL O-RING
Coat the 3 new O-rings with ATF, and install them to the direct clutch drum and direct clutch piston.
2. INSTALL DIRECT CLUTCH DRUM AND DIRECT CLUTCH PISTON

NOTICE: Be careful not to damage the O-ring and lip seal.





3. INSTALL PISTON RETURN SPRING
a. Install the direct clutch return spring on the direct clutch piston.
b. Place SST on the piston return spring and compress the springs with a press.
SST 09387-00020
c. Using a snap ring expander, install the snap ring from the direct clutch drum.

NOTICE:
- Stop the press when the spring sheet is lowered to the place 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove, preventing the spring sheet from the deforming.
- Do not expand the snap ring excessively.





4. INSTALL FLANGE, DISC AND PLATE
Install the 3 discs and 4 flanges.
Install in order: D = Disc, F = Flange
F - D - F - D - F - D - F





5. INSTALL SNAP RING
Using a screwdriver, install the snap ring.





6. INSTALL FLANGE, DISC AND PLATE
a. U340E:
Install the 2 plates, 2 discs and flange.
b. U341E:
Install the 3 plates, 3 discs and flange.
Install in order: P = Plate, D = Disc, F = Flange
U340E: P - D - P - D - F
U341E: P - D - P - D - P - D - F





7. INSTALL SNAP RING
Using a screwdriver, install the snap ring.





8. CHECK PACK CLEARANCE OF REVERSE CLUTCH
a. Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover.
b. Using a dial indicator, measure the reverse clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi)
Pack clearance: 0.86 - 1.26 mm (0.0339 - 0.0496 inch)
If the pack clearance is less than the limit of pack clearance, parts may have been assembled incorrectly, so check and reassemble again.
If the pack clearance is non-standard, select another flange.

HINT: There are 4 flanges in different thickness.





Flange Thickness: mm (inch)





9. CHECK PACK CLEARANCE OF DIRECT CLUTCH
a. Install the direct and reverse clutch and thrust needle roller bearing on the transaxle rear cover.
b. Using a dial indicator and measuring terminal Special Service Tool (SST), measure the forward clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi)
SST 09350-36010 (09350-06120)

HINT: The direct and reverse clutch will come out as you apply the compressed air. Therefore, while the checking is being done, press on the input shaft of the direct and reverse clutch using stamping machine or alike so that the pressure is not applied on the direct and reverse clutch.

Pack clearance: 0.62 - 1.02 mm (0.0244 - 0.0402 inch)
If the pack clearance is less than the limit of pack clearance, parts may have been assembled incorrectly, so check and reassemble again.
If the pack clearance is non-standard, select another flange.

HINT: There are 4 flanges in different thickness.





Selected flange thickness: mm (inch)


pro multis · About Operation CHARM