Clutch: Service and Repair

CLUTCH UNIT

COMPONENTS:

REMOVAL
1. REMOVE MANUAL TRANSAXLE ASSEMBLY
2. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY
(a) Remove the clutch release fork with the clutch release bearing from the manual transaxle.
3. REMOVE CLUTCH RELEASE FORK BOOT
4. REMOVE CLUTCH RELEASE BEARING ASSEMBLY
(a) Remove the clutch release bearing from the clutch release fork.
5. REMOVE RELEASE BEARING HUB CLIP
6. REMOVE RELEASE FORK SUPPORT
(a) Remove the release fork support from the manual transaxle.





7. REMOVE CLUTCH COVER ASSEMBLY
(a) Align the matchmark on the clutch cover assembly with the one on the flywheel.
(b) Loosen each set bolt one turn at a time until the spring tension is released.
(c) Remove the set bolts and pull off the clutch cover.

NOTICE: Do not drop the clutch disc.

8. REMOVE CLUTCH DISC ASSEMBLY

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 onto the transaxle assembly.

NOTICE: Insert the clutch disc assembly in the correct direction.





(c) Using a dial gauge, measure the clutch disc assembly runout.
Maximum runout: 0.8 mm (0.031 in.)
If necessary, replace the clutch disc assembly.





2. INSPECT CLUTCH COVER ASSEMBLY
(a) Using vernier calipers, measure the depth and width of the diaphragm spring wear.
Maximum:
A (Depth): 0.5 mm (0.020 in.)
B (Width): 6.0 mm (0.236 in.)
If necessary, replace the clutch cover assembly.





3. INSPECT FLYWHEEL SUB-ASSEMBLY
(a) Using a dial gauge, check 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 and wear.

HINT: If necessary, replace the release bearing assembly.

INSTALLATION





1. INSTALL CLUTCH DISC ASSEMBLY
(a) Insert SST into the clutch disc assembly, then insert them both into the flywheel sub-assembly.
SST 09301-00110

NOTICE: Insert the clutch disc assembly in the correct direction.





2. INSTALL CLUTCH COVER ASSEMBLY
(a) Align the matchmark on the clutch cover assembly with that on the flywheel sub-assembly.
(b) Following the procedures shown in the illustration, tighten the 6 bolts in order, starting with the bolt located near the knock pin at the top.
Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf)

HINT:
^ Following the order in the illustration, tighten the blots evenly one at a time.
^ Move SST up and down, right and left lightly after checking that the disc is in the center, and tighten the bolts.

SST 09301-00110





3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
(a) Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.
Maximum non-alignment: 0.5 mm (0.020 in.)





(b) If the 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 onto the transaxle assembly.
Torque: 37 N*m (375 kgf*cm, 27 ft.*lbf)
5. INSTALL CLUTCH RELEASE FORK BOOT
6. INSTALL RELEASE BEARING HUB CLIP





7. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
(a) Apply release hub grease to the contact surfaces of the release fork and release bearing assembly, release fork and push rod, and release fork and fork support.
Sealant: Toyota Genuine Release Hub Grease or Equivalent
(b) Install the release fork onto the release bearing assembly.





8. INSTALL CLUTCH RELEASE BEARING ASSEMBLY
(a) Apply clutch spline grease to the input shaft spline.
Sealant: Toyota Genuine Clutch Spline Grease or Equivalent

NOTICE: Do not apply grease to portion A shown in the illustration.

(b) Install the clutch release bearing with release fork onto the transaxle assembly.

NOTICE: After the installation, move the fork forward and backward to check that the release bearing slides smoothly.

9. INSTALL MANUAL TRANSAXLE ASSEMBLY