Clutch: Service and Repair
CLUTCH UNITCOMPONENTS:
REMOVAL
1. REMOVE MANUAL TRANSAXLE ASSEMBLY
2. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY
(a) Remove the clutch release fork with clutch release bearing from transaxle assembly.
3. REMOVE CLUTCH RELEASE BEARING ASSEMBLY
(a) Remove the clutch release bearing assembly from the clutch release fork.
4. REMOVE RELEASE FORK SUPPORT
(a) Remove the release fork support from the transaxle assembly.
5. REMOVE RELEASE BEARING HUB CLIP
6. REMOVE CLUTCH RELEASE FORK BOOT
7. REMOVE CLUTCH COVER ASSEMBLY
(a) Align the matchmark on the clutch cover assembly with the one on the flywheel sub-assembly.
(b) Loosen each set bolt one turn at a time until spring tension is released.
(c) Remove the 6 bolts, and pull off the clutch cover assembly.
NOTICE: Do not drop the clutch disc assembly.
8. REMOVE CLUTCH DISC ASSEMBLY
NOTICE: Keep the lining part of the clutch disc assembly, the pressure plate and surface of the flywheel sub-assembly away from oil and foreign attachment.
INSPECTION
1. INSPECT CLUTCH DISC ASSEMBLY
(a) Using vernier calipers, measure the rivet head depth.
Minimum rivet depth: 0.3 mm (0.012 in.)
If necessary, replace the clutch disc assembly.
(b) Install the clutch disc assembly to the transaxle assembly.
NOTICE: Take care not to insert the clutch disc assembly in the wrong direction.
(c) Using a dial indicator, check the clutch disc assembly runout.
Maximum runout: 0.8 mm (0.032 in.)
If necessary, replace the clutch disc assembly.
2. INSPECT CLUTCH COVER ASSEMBLY
(a) Using vernier calipers, inspect the diaphragm spring for depth and width of wear.
Minimum:
A (Depth): 0.5 mm (0.020 in.)
B (Width): 6.0 mm (0.236 in.)
If necessary, replace clutch cover assembly.
3. INSPECT FLYWHEEL SUB-ASSEMBLY
(a) Using a dial indicator, inspect the flywheel sub-assembly runout.
Maximum runout: 0.1 mm (0.004 in.)
If necessary, replace the flywheel sub-assembly.
4. INSPECT CLUTCH RELEASE BEARING ASSEMBLY
(a) Check that the clutch release bearing assembly moves smoothly without abnormal resistance by turning the sliding parts of the clutch release bearing assembly (contact surfaces with the clutch cover) while applying force in the axial direction.
(b) Inspect the clutch release bearing assembly for damage or wear.
HINT: Replace the release bearing assembly if necessary.
INSTALLATION
1. INSTALL CLUTCH DISC ASSEMBLY
(a) Insert SST in the clutch disc assembly, then insert them in the flywheel sub-assembly.
SST 09301-00210
NOTICE: Take care not to insert clutch disc assembly in the wrong direction.
2. INSTALL CLUTCH COVER ASSEMBLY
(a) Align the matchmarks on the clutch cover assembly and flywheel sub-assembly.
(b) Following the procedures shown in the illustration, tighten the 6 bolts, in the order starting the bolt locating near the knock pin on the top.
Torque: 19 Nm (195 kgf/cm, 14 ft. lbs.)
HINT:
^ Following the order in the illustration, tighten the bolts at a time evenly.
^ Move SST up and down, right and left lightly, after checking that the disc is in the center, tighten the bolts.
3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
(a) Using a dial indicator with roller instrument, check the diaphragm spring tip alignment.
Maximum non-alignment: 0.5 mm (0.020 in.)
If alignment is not as specified, using SST, adjust the diaphragm spring tip alignment.
SST 09333-00013
4. INSTALL RELEASE FORK SUPPORT
(a) Install the release fork support to the transaxle assembly.
Torque: 37 Nm (375 kgf/cm, 27 ft. lbs.)
5. INSTALL RELEASE BEARING HUB CLIP
6. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
(a) Apply release hub grease to the release fork and release bearing assembly contact, release fork and push rod contact and release fork pivot points.
Grease: Toyota Genuine Release Hub Grease or equivalent
7. INSTALL CLUTCH RELEASE BEARING ASSEMBLY
(a) Apply the clutch spline grease to the input shaft spline.
Grease: Toyota Genuine Clutch Spline Grease or equivalent
(b) Install the bearing to the release fork, and then install them to the transaxle assembly.
NOTICE: After the installation, move the folk forward and backward to check that the release bearing slides smoothly.
8. INSTALL CLUTCH RELEASE FORK BOOT
9. INSTALL MANUAL TRANSAXLE ASSEMBLY