Toyota Clutch Manual

CL–1
CLUTCH
CL–2
CLUTCH
–
PREPARATION
PREPARATION
SST (SPECIAL SERVICE TOOLS)
09023–00100
Union Nut Wrench 10 mm
09301–00110
Clutch Guide Tool
09303–35011
Input Shaft Front Bearing Puller
09304–30012
Input Shaft Front Bearing
Replacer
09333–00013
Clutch Diaphragm Spring Aligner
Clutch line
2JZ–GE Only
RECOMMENDED TOOLS
09082–00050
TOYOTA Electrical Tester Set
09905–00012
Snap Ring No. 1 Expander
EQUIPMENT
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Calipers
Dial indicator
Torque wrench
Parts Name
Trouble
Clutch grabs/chatters
Clutch pedal spongy
Clutch noisy
Clutch slips
Clutch does not disengage
CL–8
CL–9
Release cylinder cup (Damaged)
CL–11
CL–17
Pilot bearing (Worn or damaged)
CL–11
CL–17
CL–11
CL–17
CL–11
CL–17
CL–11
CL–17
CL–11
CL–17
CL–11
CL–17
CL–11
CL–17
CL–15
CL–21
CL–11
CL–17
CL–15
CL–20
CL–11
CL–17
Clutch disc (Runout is excessive)
Clutch disc (Lining broken)
Clutch disc (Dirty or burred)
Clutch disc (Oily)
Clutch disc (Worn out)
Clutch disc torsion rubber (Damaged)
Clutch disc (Glazed)
Clutch disc (Lack of spline grease)
Diaphragm spring (Damaged)
Diaphragm spring (Out of tip alignment)
Pressure plate (Distortion)
Flywheel (Distortion)
CL–11
CL–17
Clutch disc (Out of true)
–
Input shaft bearing (Worn or damaged)
CL–11
CL–17
Release bearing (Worn, dirty or damaged)
Engine mounting (loosen)
CL–6
master cylinder cup (Damaged)
Clutch line (Air in line)
CL–4
See page
Clutch pedal (freeplay out of adjustment)
CLUTCH
TROUBLESHOOTING
CL–3
TROUBLESHOOTING
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
CL–4
CLUTCH
–
CLUTCH PEDAL
CLUTCH PEDAL
CLUTCH PEDAL CHECK AND ADJUSTMENT
1.
CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
146.2–156.2 mm (5.76–6.15 in.)
2.
3.
IF NECESSARY, ADJUST PEDAL HEIGHT
Loosen the lock nut and clutch switch until the height is correct. Tighten the lock nut.
HINT: Before rotating the clutch switch for pedal height adjustment, disconnect the clutch switch connector.
CHECK PEDAL FREEPLAY AND PUSH ROD PLAY
Push in on the pedal until the beginning of clutch resistance
is felt.
Pedal freeplay: 5.0–15.0 mm (0.197–0.591 in.)
Gently push on the pedal until the resistance begins to increase a little.
Push rod play at pedal top:
1.0–5.0 mm (0.039–0.197 in.)
4.
IF NECESSARY, ADJUST PEDAL FREEPLAY AND PUSH
ROD PLAY
(a) Loosen the lock nut and turn the push rod until the freeplay
and push rod play are correct.
(b) Tighten the lock nut.
(c) After adjusting the pedal freeplay, check the pedal height.
5. INSPECT FULL PEDAL STROKE
Full pedal stroke: 132.0–138.0 mm (5.20–5.43 in.)
6.
(a)
(b)
(c)
INSPECT CLUTCH RELEASE POINT
Pull the parking brake lever and install wheel stopper.
Start the engine and idle the engine.
Without depressing the clutch pedal, slowly shift the shift
lever into position until the gears contact.
(d) Gradually depress the clutch pedal and measure the stroke
distance from the point the gear noise stops (release point)
up to the full stroke end position.
Standard distance: 25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance is not as specified, do the following operation.
• Inspect pedal height.
• Inspect push rod play and pedal freeplay.
• Bleed the clutch line.
• Inspect the clutch cover and disc.
CL–5
CLUTCH
–
CLUTCH PEDAL
7. CHECK CLUTCH START SYSTEM
(a) Check that the engine does not start when the clutch pedal
is released.
(b) Check that the engine starts when the clutch pedal is fully
depressed.
If necessary, adjust or replace the clutch start switch.
8. INSPECT CONTINUITY OF CLUTCH START SWITCH
(a) Check that there is continuity between terminals when the
switch is ON (pushed).
(b) Check that there is no continuity between terminals when the
switch is OFF (free).
If continuity is not as specified, replace the switch.
CL–6
CLUTCH
–
CLUTCH MASTER CYLINDER
CLUTCH MASTER CYLINDER
COMPONENTS
MASTER CYLINDER REMOVAL
1.
2.
Installation is in the reverse order of removal.
DRAIN OUT FLUID WITH SYRINGE
INSTALLATION HINT: After installation, adjust the clutch
pedal and bleed the clutch system.
DISCONNECT CLUTCH LINE UNION
Using SST, disconnect the union nut.
SST 09023–00100
Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf)
3.
4.
REMOVE CLIP AND PIN
REMOVE 2 MOUNTING NUTS AND PULL OUT MASTER
CYLINDER
Torque: 12 N⋅m (125 kgf⋅cm, 9 ft⋅lbf)
CL–7
CLUTCH
–
CLUTCH MASTER CYLINDER
MASTER CYLINDER DISASSEMBLY
1. REMOVE RESERVOIR TANK
(a) Using a pin punch and hammer, drive out the slotted spring
pin.
(b) Remove the reservoir tank and grommet.
2. REMOVE PUSH ROD
(a) Pull back the boot, and using snap ring pliers, remove the
snap ring.
(b) Pull out the push rod.
3. REMOVE PISTON
MASTER CYLINDER ASSEMBLY
1.
2.
3.
COAT PARTS WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
INSERT PISTON INTO CYLINDER
INSTALL PUSH ROD ASSEMBLY WITH NEW SNAP RING
4. INSTALL RESERVOIR TANK
(a) Install the reservoir tank and a new grommet.
(b) Using a pin punch and hammer, drive in the slotted spring pin.
CL–8
CLUTCH
–
CLUTCH RELEASE CYLINDER (2JZ–GTE)
CLUTCH RELEASE CYLINDER
(2JZ–GTE)
COMPONENTS
RELEASE CYLINDER REMOVAL
1.
Installation is in the reverse order of removal.
INSTALLATION HINT: After installation, adjust the clutch
pedal and bleed the clutch system.
REMOVE CLUTCH HOUSING COVER LH
Remove the 2 bolts.
Torque: 12 N⋅m (120 kgf⋅cm, 9 ft⋅lbf)
2.
DISCONNECT CLUTCH LINE
Using SST, disconnect the clutch line union. Use a container
to catch the fluid.
SST 09023–00100
Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf)
3.
REMOVE 2 BOLTS AND PULL OUT RELEASE CYLINDER
Torque: 12 N⋅m (120 kgf⋅cm, 9 ft⋅lbf)
CL–9
CLUTCH
–
CLUTCH RELEASE CYLINDER (2JZ–GTE, 2JZ–GE)
RELEASE CYLINDER DISASSEMBLY
1.
2.
PULL OUT PUSH ROD WITH BOOT
REMOVE PISTON WITH SPRING
Using compressed air, remove the piston and spring from the
cylinder.
RELEASE CYLINDER ASSEMBLY
1.
2.
3.
COAT PISTON WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
INSTALL PISTON WITH SPRING INTO CYLINDER
INSTALL BOOT WITH PUSH ROD TO CYLINDER
CLUTCH RELEASE CYLINDER
(2JZ–GE)
COMPONENTS
CL–10
CLUTCH
–
CLUTCH RELEASE CYLINDER (2JZ–GE)
RELEASE CYLINDER REMOVAL
1.
Installation is in the reverse order of removal.
INSTALLATION HINT: After installation, adjust the clutch
pedal and bleed the clutch system.
DISCONNECT CLUTCH LINE
Using SST, disconnect the clutch line union. Use a container
to catch the fluid.
SST 09023–00100
Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf)
2.
REMOVE RELEASE CYLINDER WITH 3 BOLTS
Torque:
A: 12 N⋅m (120 kgf⋅cm, 9 ft⋅lbf)
B: 4.9 N⋅m (50 kgf⋅cm, 43 in.⋅lbf)
RELEASE CYLINDER DISASSEMBLY
1.
2.
PULL OUT PUSH ROD WITH BOOT
REMOVE PISTON WITH SPRING
Using compressed air, remove the piston and spring from the
cylinder.
RELEASE CYLINDER ASSEMBLY
1.
2.
3.
COAT PISTON WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
INSTALL PISTON WITH SPRING INTO CYLINDER
INSTALL BOOT WITH PUSH ROD TO CYLINDER
CL–11
CLUTCH
–
CLUTCH RELEASE CYLINDER(2JZ–GTE)
CLUTCH UNIT (2JZ–GTE)
COMPONENTS
CLUTCH UNIT REMOVAL
1.
REMOVE TRANSMISSION FROM ENGINE
(See page MT2–5)
HINT: Do not drain the transmission oil.
2. REMOVE RELEASE FORK ASSEMBLY
(a) Remove the release fork assembly from the left side of clutch
housing service hole.
(b) Remove the E–ring from the release fork.
(c) Remove the pin and wave washer from the release fork.
CL–12
CLUTCH
3.
4.
5.
(a)
(b)
–
CLUTCH UNIT (2JZ–GTE)
REMOVE CLUTCH DISC
REMOVE CLUTCH COVER ASSEMBLY
REMOVE CLUTCH RELEASE BEARING HUB
Using a snap ring expander, remove the snap ring.
Remove the release bearing hub, thrust cone spring and
plate washer.
6. REMOVE CLUTCH RELEASE BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the release bearing, wave washer and plate washer.
CLUTCH PARTS INSPECTION AND
REPAIR
1.
INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using calipers, measure the rivet head depth.
Minimum rivet depth:
0.3 mm (0.012 in.)
If a problem is found, replace the clutch disc.
2.
INSPECT CLUTCH DISC RUNOUT
Using a dial indicator, check the disc runout.
Maximum runout:
0.8 mm (0.031 in.)
If runout is excessive, replace the clutch disc.
3.
INSPECT FLYWHEEL RUNOUT
Using a dial indicator, check the flywheel runout.
Maximum runout:
0.1 mm (0.004 in.)
If runout excessive, replace the flywheel.
CL–13
CLUTCH
4.
–
CLUTCH UNIT (2JZ–GTE)
INSPECT PILOT BEARING
Turn the bearing by hand while applying force in the axial
direction.
If the bearing sticks or has much resistance, replace the pilot
bearing.
5. IF NECESSARY, REPLACE PILOT BEARING
(a) Remove the 2 bolts at diametrically opposite points.
(b) Using SST, remove the pilot bearing.
SST 09303–35011
(c)
Using SST and a hammer, drive in a new pilot bearing.
SST 09301–00110
(d) Install 2 new bolts.
(e) First, torque the 2 bolts uniformly a little at a time.
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)
(f)
Then tighten the 2 bolts an additional 80–100°.
CL–14
CLUTCH
6.
–
CLUTCH UNIT (2JZ–GTE)
INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth and
width of wear.
Maximum:
A: Depth 0.6 mm (0.024 in.)
B: Width 5.0 mm (0.197 in.)
If necessary, replace the clutch cover.
7.
INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial
direction.
HINT: The bearing is permanently lubricated and requires no
cleaning or lubrication.
If a problem is found, replace the bearing together with the
hub.
8.
INSPECT FLYWHEEL DAMPER FOR GREASE LEAKAGE
If grease has sprayed onto the clutch housing, replace the flywheel assembly.
9. INSPECT FLYWHEEL DAMPER ROTATIONAL
FREEPLAY
(a) Install the 2 bolts to the secondary flywheel at diametrically
opposite positions.
(b) Holding both the bolts, turn the secondary flywheel clockwise
until it stops.
(c)
Put matchmarks on the primary and secondary fly–wheels at
this position.
(d) Then rotate the primary flywheel counterclockwise by hand
until it stops.
(e) Put matchmarks on the primary flywheel at this position.
(f) Measure the circumferential length between the 2
matchmarks on the secondary flywheel.
Standard:
105 mm (4.134 in.)
(g) Repeat the preceding steps (d) to (f) 4 times and if the
measurement is greater than the maximum length replace
the flywheel assembly.
(See page EG–122)
CL–15
CLUTCH
–
CLUTCH UNIT (2JZ–GTE)
CLUTCH UNIT INSTALLATION
1. INSTALL CLUTCH DISC AND COVER ON FLY–WHEEL
(a) Insert SST in the clutch disc, and then set them and the cover
in position.
SST 09301–00110
(b) Align the matchmarks on the clutch cover and fly–wheel.
(c) Tighten the bolts evenly and gradually while pushing the SST.
Make several passes around the cover until it is snug.
(d) Torque the bolts on the clutch cover in the order shown.
Torque: 19 N⋅m (195 kgf⋅cm, 14 ft⋅lbf)
HINT: Temporarily tighten the No.1 and No.2 bolts.
2.
CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the diaphragm spring tip alignment.
Maximum non–alignment:
0.5 mm (0.020 in.)
3.
If alignment is not as specified, use the SST to adjust the diaphragm spring tip alignment.
SST 09333–00013
REMOVE CLUTCH COVER AND CLUTCH DISC
4. INSTALL CLUTCH RELEASE FORK
(a) Install the wave washer and pin to release fork.
(b) Install a new E–ring.
5.
APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE
GREASE (NLGI NO.2)
(a) Apply release hub grease to these parts:
• Release fork and hub contact point
• Release fork and push rod contact point
• Release fork pivot point
CL–16
CLUTCH
–
•
•
CLUTCH UNIT (2JZ–GTE)
Release bearing hub inside groove
Release bearing front surface
(b) Apply clutch spline grease.
• Clutch disc spline
HINT: Recommended grease part number 08887–01706.
6. INSTALL CLUTCH RELEASE BEARING
(a) Install the release bearing hub, wave washer and plate
washer.
(b) Using a snap ring expander, install a new snap ring.
7. INSTALL CLUTCH RELEASE BEARING HUB
(a) Install the thrust cone washer and plate washer to release
bearing hub.
NOTICE: Install the thrust cone washer in correct direction.
(b) Install the release bearing hub to release bearing.
(c) Using a snap ring expander, install a new snap ring.
CL–17
CLUTCH
8.
9.
–
CLUTCH UNIT (2JZ–GTE, 2JZ–GE)
INSTALL CLUTCH COVER ASSEMBLY
INSTALL CLUTCH DISC
NOTICE: Install the clutch disc in the correct direction.
10. INSTALL RELEASE FORK ASSEMBLY
Install the release bearing assembly to the release fork assembly, and then install them to the transmission.
11. INSTALL TRANSMISSION TO ENGINE
(See page MT2–5)
CLUTCH UNIT (2JZ–GE)
COMPONENTS
CL–18
CLUTCH
–
CLUTCH UNIT (2JZ–GE)
CLUTCH UNIT REMOVAL
1.
REMOVE TRANSMISSION FROM ENGINE
(See page MT1–8)
HINT: Do not drain the transmission oil.
2. REMOVE CLUTCH COVER AND DISC
(a) Place matchmarks on the flywheel and clutch cover.
(b) Loosen each set bolt one turn at a time until spring tension
is released.
(c)
Remove the set bolts, and pull off the clutch cover with the
clutch disc.
NOTICE: Do not drop the clutch disc.
3. REMOVE RELEASE BEARING, FORK AND BOOT FROM
TRANSMISSION
(a) Remove the clips, and pull off the bearing and hub.
(b) Remove the fork and boot.
CLUTCH PARTS INSPECTION AND
REPAIR
1.
INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using calipers, measure the rivet head depth.
Minimum rivet depth:
0.3 mm (0.012 in.)
If a problem is found, replace the clutch disc.
2.
INSPECT CLUTCH DISC RUNOUT
Using a dial indicator, check the disc runout.
Maximum runout:
0.8 mm (0.031 in.)
If runout is excessive, replace the clutch disc.
3.
INSPECT FLYWHEEL RUNOUT
Using a dial indicator, check the flywheel runout.
Maximum runout:
0.1 mm (0.004 in.)
If runout excessive, replace the flywheel.
CL–19
CLUTCH
4.
–
CLUTCH UNIT (2JZ–GE)
INSPECT PILOT BEARING
Turn the bearing by hand while applying force in the axial
direction.
If the bearing sticks or has much resistance, replace the pilot
bearing.
5. IF NECESSARY, REPLACE PILOT BEARING
(a) Remove the 2 bolts at diametrically opposite points.
(b) Using SST, remove the pilot bearing.
SST 09303–35011
(c)
Using SST and a hammer, drive in a new pilot bearing.
SST 09304–30012
(d) Install 2 new bolts.
(e) First, torque the 2 bolts uniformly a little at a time.
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)
(f)
Then tighten the 2 bolts an additional 80–100°.
CL–20
CLUTCH
6.
–
CLUTCH UNIT (2JZ–GE)
INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth and
width of wear.
Maximum:
A: Depth 0.6 mm (0.024 in.)
B: Width 5.0 mm (0.197 in.)
If necessary, replace the clutch cover.
7.
INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial
direction.
HINT: The bearing is permanently lubricated and requires no
cleaning or lubrication.
If a problem is found, replace the bearing together with the
hub.
CLUTCH UNIT INSTALLATION
1.
INSTALL CLUTCH DISC AND CLUTCH COVER ON
FLYWHEEL
(a) Insert the SST in the clutch disc, and then set them and the
cover in position.
SST 09301–00110
(b) Align the matchmarks on the clutch cover and fly–wheel.
(c) Tighten the bolts evenly and gradually while pushing SST.
Make several passes around the cover until it is snug.
(d) Torque the bolts on the clutch cover in order shown.
Torque: 19 N⋅m (195 kgf⋅cm, 14 ft⋅lbf)
HINT: Temporarily tighten the No.1 and No.2 bolts.
2.
CHECK DIAPHRAGM SPRING TIP ALIGNMENT
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
CL–21
CLUTCH
3.
(a)
(b)
4.
(a)
(b)
5.
–
CLUTCH UNIT (2JZ–GE)
APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE
GREASE (NLGI NO.2)
Apply release hub grease to these parts:
• Release fork and hub contact point
• Release fork and push rod contact point
• Release fork pivot point
Apply clutch spline grease.
• Clutch disc spline
HINT: Recommended grease part number 08887–01706.
INSTALL RELEASE BEARING, FORK AND BOOT TO
TRANSMISSION
Install the bearing assembly to the fork, and then install them
to the transmission.
Install the boot.
INSTALL TRANSMISSION TO ENGINE
(See page MT1–8)
CL–22
CLUTCH
–
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
SERVICE DATA
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Pedal height from asphalt sheet
146.2–156.2 mm (5.76–6.15 in.)
Pedal freeplay
5.0–15.0 mm (0.197–0.591 in.)
Push rod play at pedal top
1.0–5.0 mm (0.039–0.197 in.)
Full pedal stroke
132.0–138.0 mm (5.20–5.43 in.)
Clutch release point from pedal full stroke end position
25 mm (0.98 in.) or more
Disc rivet head depth
Maximum
0.3 mm (0.012 in.)
Disc runout
Maximum
0.8 mm (0.031 in.)
Diaphragm spring out non–alignment
Maximum
0.5 mm (0.020 in.)
Diaphragm spring finger wear
Depth Maximum
0.6 mm (0.024 in.)
Diaphragm spring finger wear
Width Maximum
5.0 mm (0.197 in.)
Flywheel runout
Maximum
0.1 mm (0.004 in.)
Flywheel damper rotational freeplay (2JZ–GTE)
Standard
105 mm (4.134 in.)
TORQUE SPECIFICATIONS
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Part tightened
N⋅m
kgf⋅cm
ft⋅lbf
Clutch cover x Flywheel
19
195
14
Master cylinder set nut
12
125
9
Release cylinder set bolt
12
120
9
Clutch tube bracket (2JZ–GE)
4.9
50
43 in.⋅lbf
Clutch line union
15
155
11
Bleeder plug
11
110
8
Flywheel set bolt
49
500
36
Release fork support (2JZ–GTE)
25
260
18
Release fork support (2JZ–GE)
39
400
29
Clutch housing cover LH (2JZ–GTE)
12
120
9
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