ac clutch gap TOYOTA CAMRY 2000 Service Repair Manual

AUTOMATIC TRANSAXLEDIRECT CLUTCH ±
AX±42
DIRECT CLUTCH INSPECTION
1. INSPECT CLUTCH PISTON
(a) Check that the check ball is free by shaking the piston.
(b) Check that the valve does not leak by applying lowpres-
sure compressed air.
2. INSPECT DISCS, PLATES AND FLANGE
Check if the sliding surfaces of the discs, plates 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 numbers are defaced, re-
place all discs.

Before assembling new discs, soak them in ATF for
at least 15 minutes.
3. CHECK DIRECT CLUTCH BUSHING
Using a dial indicator, measure the inside diameter of the
direct clutch bushing.
Maximum inside diameter:
47.07 mm (1.8531 in.)
If the inside diameter is greater than the maximum, re-
place the direct clutch.
DIRECT CLUTCH ASSEMBLY
1. INSTALL CLUTCH PISTON IN DIRECT CLUTCH DRUM
(a) Install new O±rings to the piston. Coat the O±rings with
AT F.
(b) Being careful not to damage the O±rings, press the piston
into the drum with the cup side up.
2. INSTALL PISTON RETURN SPRING
(a) Place the return spring and snap ring onto the piston.
(b) Place SST on the spring retainer, and compress the re-
turn spring with a shop press.
SST 09350±32014 (09351±32070)
(c) Install the snap ring with the snap ring pliers. Be sure the
end gap of snap ring is not aligned with the spring retainer
claw.
AX0F8±02
AX0F9±02

AUTOMATIC TRANSAXLEDIRECT CLUTCH ±
AX±43
3. INSTALL PLATES, DISCS AND FLANGE
(a) Install plates and discs.
Install in order: P=Plate D=Disc
P ± D ± P ± D ± P ± D
(b) Install the flange with the flat end facing downward.
4. INSTALL SNAP RING
Check that the end gap of the snap ring is not aligned with
one of the cutouts.
5. RECHECK PISTON STROKE OF DIRECT CLUTCH
(a) Install the direct clutch on the oil pump.
(b) Set a dial indicator and measuring terminal (SST) togeth-
er, measure the direct clutch piston stroke while applying
and releasing compressed air (392 ± 785 kPa, 4 ± 8 kgf/
cm
2, 57 ± 114 psi).
SST 09350±32014 (09351±32190)
Piston stroke:
1.11 ± 1.44 mm (0.0437 ± 0.0567 in.)
If the piston stroke is non±standard, select another
flange.
HINT: There are 2 different flange thickness.
Flange thickness:
2.60 mm (0.1024 in.)
3.00 mm (0.1181 in.)

AUTOMATIC TRANSAXLEFORWARD CLUTCH ±
AX±47
2. INSTALL CLUTCH PISTON TO CLUTCH DRUM
(a) Install the 2 new O±rings to the piston.
(b) Coat the O±rings with ATF.
(c) Press the piston into the drum with the cup side up, being
careful not to damage the O±rings.
3. INSTALL PISTON RETURN SPRINGS
(a) Place the piston return spring and snap ring onto the pis-
ton.
(b) Place SST on the piston return spring, and compress the
springs with a shop press.
SST 09350±32014 (09351±32070)
(c) Install the snap ring with snap ring pliers.
Be sure the end gap of the snap ring is not aligned with
the spring retainer claw.
4. INSTALL PLATES, DISCS AND FLANGE
(a) Install the plates and discs.
Install in order: P=Plate D=Disc
P ± D ± P ± D ± P ± D ± P ± D
(b) Install the flange with the flat end facing downward.
5. INSTALL SNAP RING
Check that the end gap of snap ring is not aligned with one
of the cutouts.

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±64
OVERDRIVE DIRECT CLUTCH ASSEMBLY
1. INSTALL CLUTCH PISTON
(a) Install new O±rings to the piston. Coat the O±rings with
AT F.
(b) Press the piston into the drum with the cup side up, being
careful not to damage the O±ring.
2. INSTALL PISTON RETURN SPRING
(a) Install the return spring and set snap ring in place.
(b) Place SST on the spring retainer, and compress the
spring with a shop press.
SST 09350±32014 (09351±32070, 09351±32200)
(c) Install the snap ring with a screwdriver. Be sure end gap
of snap ring is aligned with the groove of the clutch drum.
3. INSTALL PLATES, DISCS AND FLANGE
Install in order: P=Plate D=Disc
Flange ± D ± P ± D ± Flange
AX0G1±02

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±65
4. INSTALL SNAP RING
Be sure end gap of the snap ring is not aligned with the
groove of the clutch drum.
5. INSTALL BEARING AND RACE
(a) Coat the bearing with petroleum jelly and install it facing
the race side downward to the clutch drum.
Bearing:
Outer diameter
46.3 mm (1.823 in.)
Inner diameter
26.2 mm (1.031 in.)
(b) Coat the race with petroleum jelly and install it to thecase.
Race:
Outer diameter
43.0 mm (1.693 in.)
Inner diameter
24.5 mm (0.965 in.)
6. INSTALL DIRECT CLUTCH ON CASE
7. RECHECK PISTON STROKE OF DIRECT CLUTCH
Using a dial indicator, measure the piston stroke while ap-
plying and releasing compressed air (392 ± 785 kPa, 4 ±
8 kgf/cm
2, 57± 114 psi).
Piston stroke:
1.21 ± 1.91 mm (0.0476 ± 0.0752 in.)

AUTOMATIC TRANSAXLECOMPONENT PARTS INSTALLATION ±
AX±109
7. INSTALL PISTON RETURN SPRING
(a) Place the return spring and snap ring on the piston.
(b) Place SST, and compress the return spring evenly by
tightening the bolt gradually.
SST 09350±32014 (09351±32040)
(c) Install snap ring. Visually check to make sure it is fully
seated and centered by the 3 lugs on the spring retainer.
Be sure the end gap of snap ring is not aligned with the
spring retainer claw.
(d) Remove SST.
8. INSTALL OVERDRIVE UNIT
(a) Install the overdrive brake apply gasket and overdrive
clutch apply gasket.
(b) Install the overdrive brake drum to the case.
(c) Install a new case gasket to the case.
(d) Make sure that the length from the top surface of the case
to the counter driven gear top surface should be about 24
mm (0.94 in.).

AUTOMATIC TRANSAXLECOMPONENT PARTS INSTALLATION ±
AX±112
(c) Coat the thrust washer with petroleum jelly and install it
onto the planetary gear.
16. CHECK OPERATION OF NO.2 ONE±WAY CLUTCH
Turn the planetary carrier. The carrier should turn freely
clockwise and lock counterclockwise.
17. INSTALL SNAP RING
Be sure the end gap of the snap ring is not aligned with
one of cutouts.
18. INSTALL SECOND COAST BRAKE BAND GUIDE
Install the 2 band guides so that its tip touches the case.
19. INSTALL SECOND BRAKE INTO CASE
(a) Install the flange, facing the flat end toward the oil pump
side.
(b) Install the discs and plates.
Install in order: P=Plate D=Disc
Flange ± D ± P ± D ± P ± D ± P

AUTOMATIC TRANSAXLEDIRECT CLUTCH ±
AX±44
(b) Place SST on the spring retainer, and compress the re-
turn spring with a press.
SST 09350±32014 (09351±32070)
(c) Install the snap ring using snap ring pliers. Be sure the
end gap of snap ring is aligned with the spring retainer
claw.
3. INSTALL PLATES, DISCS AND FLANGE
(a) Install plates and discs.
Install in order:
P=Plate D=Disc
P±D±P±D±P±D
(b) Install the flange with the flat end facing downward.
4. INSTALL SNAP RING
Check that the end gap of the snap ring is not aligned with
one of the cutouts.
5. RECHECK PISTON STROKE OF DIRECT CLUTCH
(a) Install the direct clutch on the oil pump.
(b) Install a dial indicator and measuring terminal (SST) to-
gether, measure the direct clutch piston stroke while ap-
plying and releasing compressed air (392±785 kPa, 4±8
kgf/cm
2, 57±114 psi).
SST 09350±32014 (09351±32190)
Piston stroke:
0.91±1.35 mm (0.0358±0.0531 in.)
If the piston stroke is non±standard, select another
flange.
HINT: There are 2 different thickness for the flange.
Flange thickness:
2.70 mm (0.1063 in.)
3.00 mm (0.1181 in.)

AUTOMATIC TRANSAXLEFORWARD CLUTCH ±
AX±48
2. INSTALL CLUTCH PISTON TO CLUTCH DRUM
(a) Install the 2 new O±rings to the piston.
(b) Coat the O±ring with ATF.
(c) Press the piston into the drum with the cup side up, being
careful not to damage the O±rings.
3. INSTALL PISTON RETURN SPRINGS
(a) Place the return spring and snap ring onto the piston.
(b) Place SST on the spring retainer, and compress the
springs with a press.
SST 09350±32014 (09351±32070)
(c) Install the snap ring with snap ring pliers.
Be sure the end gap of the snap ring is not aligned with
the spring retainer claw.
4. INSTALL PLATES, DISCS AND FLANGE
(a) Install the plates and discs.
Install in order:
P=Plate D=Disc
P±D±P±D±P±D±P±D±P±D
(b) Install the flange with the flat end facing downward.
5. INSTALL SNAP RING
Check that the end gap of snap ring is not aligned with one
of the cutouts.

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±64
(b) Press the piston into the drum with the cup side up, being
careful not to damage the O±ring.
2. INSTALL PISTON RETURN SPRING
(a) Install the return spring and seat snap ring in place.
(b) Place SST on the spring retainer, and compress the
spring with a press.
SST 09350±32014 (09351±32070, 09351±32200)
(c) Install the snap ring with a screwdriver. Be sure end gap
of snap ring is aligned with the groove of the clutch drum.
3. INSTALL PLATES, DISCS AND FLANGE
Install in order:
P=Plate D=Disc
P±D±P±D±Flange
4. INSTALL SNAP RING
Be sure end gap of the snap ring is not aligned with the
groove of the clutch drum.