FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.
Home >> Lexus >> 2009 >> IS 250 RWD V6-2.5L (4GR-FSE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Service and Repair >> Overhaul >> Clutch Drum and Input Shaft Assembly >> Reassembly

Reassembly








A960E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: REASSEMBLY

REASSEMBLY

1. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY





(a) Coat 2 new O-rings with ATF, and install them in the direct clutch piston.
(b) Coat a new O-ring with ATF, and install it to the No. 2 clutch balancer.





(c) Install the No. 2 clutch balancer and the direct clutch return spring to the direct clutch piston sub-assembly.
(d) Press the direct clutch piston into the reverse clutch drum sub-assembly by hands.
NOTE:
Do not damage the O-rings.





(e) Place SST on the direct clutch piston, and compress the return spring with a press.
SST: 09320-89010
SST: 09350-30020
09350-07070
(f) Install the snap ring with a snap ring expander.
NOTICE:
- Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
- Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.
- Do not expand the snap ring excessively.





(g) Set the end gap of the snap ring in the piston as shown in the illustration.
2. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY





(a) Coat a new O-ring with ATF, and install it on the reverse clutch drum sub-assembly.





(b) Coat a new O-ring with ATF, and install it on the reverse clutch piston sub-assembly.





(c) Press the clutch drum sub-assembly into the reverse clutch piston with both hands.
NOTE:
Do not damage the O-ring.

3. INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY
(a) Coat a new O-ring with ATF, and install it on the reverse clutch piston sub-assembly.





(b) Install the reverse clutch return spring onto the reverse clutch piston sub-assembly.
4. INSTALL NO. 3 CLUTCH BALANCER





(a) Install the No. 3 clutch balancer to the reverse clutch return spring.
(b) Place SST on the No. 3 clutch balancer, and compress the clutch balancer with a press.
SST: 09387-00070
(c) Install the snap ring with a snap ring expander.
SST: 09350-30020
09350-07070
NOTICE:
- Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
- Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.
- Do not expand the snap ring excessively.





(d) Set the end gap of the snap ring in the piston as shown in the illustration.
5. INSTALL NO. 2 DIRECT CLUTCH DISC





(a) Install the reverse clutch flange, the 5 plates and the 5 discs on the reverse clutch drum sub-assembly.
Install in order:
P = Plate, D = Disc, F = Flange,
F - D - P - D - P - D - P - D - P - D - P





(b) Using a screwdriver, install the 2 hole snap rings on the reverse clutch drum sub-assembly.
6. INSPECT PACK CLEARANCE OF DIRECT CLUTCH Clutch Drum and Input Shaft Assembly
7. INSTALL REVERSE CLUTCH FLANGE





(a) Install the reverse clutch flange to the reverse clutch drum sub-assembly.
8. INSTALL REVERSE CLUTCH REACTION SLEEVE





(a) Install the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 4 reverse clutch discs, and the 3 clutch plates to the reverse clutch hub.
Install in order:
P = Plate, D = Disc, F = Flange, S = Sleeve, C = Cushion Plate
S - C - F - D - P - D - P - D - P - D
(b) Using a screwdriver, install the hole snap ring.
9. INSPECT PACK CLEARANCE OF REVERSE CLUTCH Clutch Drum and Input Shaft Assembly
10. REMOVE REVERSE CLUTCH REACTION SLEEVE





(a) Using a screwdriver, remove the snap ring from the reverse clutch drum sub-assembly.





(b) Remove the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 4 reverse clutch discs, and the 3 clutch plates from the reverse clutch hub sub-assembly.
11. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY





(a) Install the coast clutch piston to the input shaft.
(b) Install a new O-ring to the forward clutch.
(c) Install the forward clutch piston sub-assembly to the input shaft.
12. INSTALL NO. 1 CLUTCH BALANCER





(a) Coat a new D-ring with ATF and install it on the No. 1 clutch balancer.





(b) Install the No. 1 clutch balancer and the forward clutch return spring sub-assembly.
NOTE:
Do not damage the D-ring.





(c) Place SST on the No. 1 clutch balancer, and compress the return spring with a press.
SST: 09350-30020
09350-07040
SST: 09316-20011
(d) Using SST, Install the snap ring.
SST: 09350-30020
09350-07070
NOTICE:
- Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
- Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.
- Do not expand the snap ring excessively.





(e) Set the end gap of the snap ring in the piston as shown in the illustration.
13. INSTALL COAST CLUTCH DISC





(a) Install the flange, the 4 discs and the 4 plates to the forward clutch piston.
(b) Using a screwdriver, install the hole snap ring.
14. INSPECT PACK CLEARANCE OF COAST CLUTCH Clutch Drum and Input Shaft Assembly
15. INSTALL NO. 1 CLUTCH DISC





(a) Install the flange, the 4 discs, 4 plates and clutch cushion plate to the input shaft assembly.
Install in order:
P = Plate, D = Disc, F = Flange, C = Cushion Plate
F - D - P - D - P - D - P - D - P - C





(b) Using a screwdriver, install the hole snap ring.





(c) Install the thrust needle roller bearing and the thrust bearing race.






16. INSTALL INPUT SHAFT OIL SEAL RING





(a) Coat 4 new oil seal rings with ATF.
(b) Squeeze the ends of the 4 oil seal rings together, and then install them to the input shaft groove.
NOTE:
Do not expand the ring ends excessively.
HINT:
After installing the oil seal rings, check that they rotate smoothly.

17. INSPECT PACK CLEARANCE OF FORWARD CLUTCH Clutch Drum and Input Shaft Assembly
18. INSTALL INPUT SHAFT





(a) Install the input shaft to the reverse clutch drum sub-assembly.





(b) Install the thrust needle roller bearing and the thrust bearing race to the reverse clutch drum sub-assembly.
Thrust needle roller bearing diameter:






19. INSTALL COAST CLUTCH HUB SUB-ASSEMBLY





(a) Install the clutch hub thrust washer and the No. 4 one way clutch assembly to the coast clutch hub.





(b) Install the coast clutch hub sub-assembly to the reverse clutch drum sub-assembly.
20. INSTALL CLUTCH HUB SUB-ASSEMBLY





(a) Install the 2 thrust needle roller bearings and No. 2 thrust bearing race to the clutch hub sub-assembly.
Bearing and race diameter:










(b) Install the clutch hub thrust washer and forward clutch hub sub-assembly to the reverse clutch drum sub-assembly.
21. INSTALL NO. 3 CLUTCH DISC





(a) Install the clutch cushion plate, the reverse clutch flange, the 3 plates and the 4 discs to the reverse clutch hub.
22. INSTALL REVERSE CLUTCH REACTION SLEEVE





(a) Install the reverse clutch reaction sleeve to the reverse clutch hub.
23. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY





(a) Install the reverse clutch hub sub-assembly, the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 4 reverse clutch discs, and the 3 clutch plates to the reverse clutch drum sub-assembly.





(b) Using a screwdriver, install the snap ring on the reverse clutch drum sub-assembly and the input shaft assembly.
pro multis Credits:Operation CHARM About Operation CHARM