Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSTOYOTA2002HIGHLANDER 4WD L4-2.4L (2AZ-FE)REPAIR AND DIAGNOSISTRANSMISSION AND DRIVETRAINAUTOMATIC TRANSMISSION/TRANSAXLESERVICE AND REPAIRDISASSEMBLY/INSPECTION/REASSEMBLY OF COMPONENTSUNDERDRIVE CLUTCH
2002 Toyota Highlander 4WD L4-2.4L (2AZ-FE)
Underdrive Clutch
2002 Toyota Highlander 4WD L4-2.4L (2AZ-FE)SECTION Underdrive Clutch
OVERHAUL
1. INSPECT UNDERDRIVE PACK CLEARANCE
a. Install the U/D clutch to the transaxle case.
NOTICE: Be careful not to damage the oil seal rings.
b. Install a dial indicator as shown in the illustration.
c. Measure the U/D clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance: 1.51 - 1.90 mm (0.0594 - 0.0748 inch)
If the pack clearance is non-standard, inspect the discs, plates and flange.
2. REMOVE UNDERDRIVE CLUTCH FLANGE NO.1 HOLE SNAP RING [34265A/98-4]
a. Using a screwdriver, remove the U/D clutch flange No. 2 snap ring.
3. REMOVE UNDERDRIVE CLUTCH DISC NO.1 [34261/98-4]
a. 1MZ-FE:
Remove the flange, 4 discs and 4 plates from the U/D clutch drum.
b. 2AZ-FE:
Remove the flange, 3 discs and 3 plates from the U/D clutch drum.
4. INSPECT UNDERDRIVE CLUTCH DISC NO.1 [34261/98-4]
a. 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.
5. INSPECT UNDERDRIVE CLUTCH DRUM SUB-ASSY [34204/98-4]
a. Using a dial indicator, measure the inside diameter of the U/D clutch drum bushing.
Standard drum bushing: 37.06 - 37.08 mm (1.4591 - 1.4598 inch)
Maximum drum bushing: 37.13 mm (1.4618 inch)
If the inside diameter is greater than the maximum, replace the U/D clutch drum.
6. REMOVE UNDERDRIVE CLUTCH DRUM O-RING [34204A/98-4]
7. REMOVE UNDERDRIVE CLUTCH PISTON SET [34205B/98-4]
a. Place SST on the clutch balancer and compress the spring with a press.
SST 0935-32014 (09351-32070)
b. Using a snap ring expander, remove the snap ring.
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 grove.
- This prevents the spring sheet from being deformed.
- Do not expand the snap ring excessively.
c. Remove the clutch balancer from the U/D clutch drum.
d. Remove the piston return spring from the U/D clutch drum.
e. Install the U/D clutch to the transaxle case.
NOTICE: Be careful not to damage the oil seal rings.
f. Holding the U/D clutch piston with your hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove the U/D clutch piston.
8. INSPECT UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSY [34206/98-4]
a. Using vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 17.14 mm (0.6752 inch)
9. INSTALL UNDERDRIVE CLUTCH PISTON SET [34205B/98-4]
a. Coat the U/D clutch piston with AFT, install it to the U/D clutch piston drum.
NOTICE: Be careful not to damage the O-ring.
b. Install the piston return spring to the U/D clutch drum.
c. Install the clutch balancer to the U/D clutch drum.
NOTICE: Be careful not to damage the lip seal of the clutch balancer.
d. Place SST on the clutch balancer and compress the piston return spring with a press.
SST 09350-32014 (09351-32070)
e. Using a snap ring expander, install the snap ring to the U/D 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 the place 1 - 2 mm (0.039 - 0.078 inch) from the snap ring grove.
- This prevents the spring sheet from being deformed.
- Do not expand the snap ring excessively.
f. Set the end gap of the snap ring in the U/D clutch drum shown in the illustration.
NOTICE: The end gap of the snap ring should not coincide with any of the stopper.
10. INSTALL UNDERDRIVE CLUTCH DRUM O-RING [34204A/98-4]
a. Coat the new O-ring with AFT, install it to the U/D clutch drum.
11. INSTALL UNDERDRIVE CLUTCH DISC NO.1 [34261/98-4]
a. 1MZ-FE:
Install the 4 plates, 4 discs and flange to the U/D clutch drum.
b. 1MZ-FE:
Install the 3 plates, 3 discs and flange to the U/D clutch drum.
12. INSTALL UNDERDRIVE CLUTCH FLANGE NO.1 HOLE SNAP RING [34265A/98-1]
a. Using a screwdriver, install the U/D clutch flange No. 2 hole snap ring.
b. Check that the end gap of snap ring is not aligned with one of the cutouts.
13. INSPECT UNDERDRIVE PACK CLEARANCE
a. Install the U/D clutch to the transaxle case.
NOTICE: Be careful not to damage the oil seal rings.
b. Set a dial indicator as shown in the illustration.
c. Measure the U/D clutch piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Park clearance: 1.51 - 1.90 mm (0.0594 - 0.0748 inch)
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 non-standard, select another flange.
HINT: There are 3 flanges in different thickness.
Flange thickness: mm (in.)
1. INSPECT UNDERDRIVE PACK CLEARANCE
a. Install the U/D clutch to the transaxle case.
NOTICE: Be careful not to damage the oil seal rings.
b. Install a dial indicator as shown in the illustration.
c. Measure the U/D clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance: 1.51 - 1.90 mm (0.0594 - 0.0748 inch)
If the pack clearance is non-standard, inspect the discs, plates and flange.
2. REMOVE UNDERDRIVE CLUTCH FLANGE NO.1 HOLE SNAP RING [34265A/98-4]
a. Using a screwdriver, remove the U/D clutch flange No. 2 snap ring.
3. REMOVE UNDERDRIVE CLUTCH DISC NO.1 [34261/98-4]
a. 1MZ-FE:
Remove the flange, 4 discs and 4 plates from the U/D clutch drum.
b. 2AZ-FE:
Remove the flange, 3 discs and 3 plates from the U/D clutch drum.
4. INSPECT UNDERDRIVE CLUTCH DISC NO.1 [34261/98-4]
a. 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.
5. INSPECT UNDERDRIVE CLUTCH DRUM SUB-ASSY [34204/98-4]
a. Using a dial indicator, measure the inside diameter of the U/D clutch drum bushing.
Standard drum bushing: 37.06 - 37.08 mm (1.4591 - 1.4598 inch)
Maximum drum bushing: 37.13 mm (1.4618 inch)
If the inside diameter is greater than the maximum, replace the U/D clutch drum.
6. REMOVE UNDERDRIVE CLUTCH DRUM O-RING [34204A/98-4]
7. REMOVE UNDERDRIVE CLUTCH PISTON SET [34205B/98-4]
a. Place SST on the clutch balancer and compress the spring with a press.
SST 0935-32014 (09351-32070)
b. Using a snap ring expander, remove the snap ring.
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 grove.
- This prevents the spring sheet from being deformed.
- Do not expand the snap ring excessively.
c. Remove the clutch balancer from the U/D clutch drum.
d. Remove the piston return spring from the U/D clutch drum.
e. Install the U/D clutch to the transaxle case.
NOTICE: Be careful not to damage the oil seal rings.
f. Holding the U/D clutch piston with your hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove the U/D clutch piston.
8. INSPECT UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSY [34206/98-4]
a. Using vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 17.14 mm (0.6752 inch)
9. INSTALL UNDERDRIVE CLUTCH PISTON SET [34205B/98-4]
a. Coat the U/D clutch piston with AFT, install it to the U/D clutch piston drum.
NOTICE: Be careful not to damage the O-ring.
b. Install the piston return spring to the U/D clutch drum.
c. Install the clutch balancer to the U/D clutch drum.
NOTICE: Be careful not to damage the lip seal of the clutch balancer.
d. Place SST on the clutch balancer and compress the piston return spring with a press.
SST 09350-32014 (09351-32070)
e. Using a snap ring expander, install the snap ring to the U/D 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 the place 1 - 2 mm (0.039 - 0.078 inch) from the snap ring grove.
- This prevents the spring sheet from being deformed.
- Do not expand the snap ring excessively.
f. Set the end gap of the snap ring in the U/D clutch drum shown in the illustration.
NOTICE: The end gap of the snap ring should not coincide with any of the stopper.
10. INSTALL UNDERDRIVE CLUTCH DRUM O-RING [34204A/98-4]
a. Coat the new O-ring with AFT, install it to the U/D clutch drum.
11. INSTALL UNDERDRIVE CLUTCH DISC NO.1 [34261/98-4]
a. 1MZ-FE:
Install the 4 plates, 4 discs and flange to the U/D clutch drum.
b. 1MZ-FE:
Install the 3 plates, 3 discs and flange to the U/D clutch drum.
12. INSTALL UNDERDRIVE CLUTCH FLANGE NO.1 HOLE SNAP RING [34265A/98-1]
a. Using a screwdriver, install the U/D clutch flange No. 2 hole snap ring.
b. Check that the end gap of snap ring is not aligned with one of the cutouts.
13. INSPECT UNDERDRIVE PACK CLEARANCE
a. Install the U/D clutch to the transaxle case.
NOTICE: Be careful not to damage the oil seal rings.
b. Set a dial indicator as shown in the illustration.
c. Measure the U/D clutch piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Park clearance: 1.51 - 1.90 mm (0.0594 - 0.0748 inch)
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 non-standard, select another flange.
HINT: There are 3 flanges in different thickness.
Flange thickness: mm (in.)
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.