Clutch de Toyota.pdf

CLUTCH

CL-1

DESCRIPTIONThe diaphragm spring turnover type clutch providing lighter release performance.

-CLUTCH DESCRIPTIONCL-2

PREPARATIONSST(SPECIAL SERVICE TOOLS)

RECOMMENDED TOOLS09082-00050 TOYOTA Electrical Tester Set

09333-00013 Clutch Diaphragm Spring Aligner

09023-00100 Union Nut Wrench 10 mm

09301-32010 Clutch Guide Tool

09905-00013 Snap Ring Pliers

EQUIPMENT

Torque wrench

Dial indicator

Clutch line tube

Calipers

-CLUTCH PREPARATIONCL-3

TR

OU

BLE

SH

OO

TIN

GU

se the table below to help you find the cause of the problem

. The num

bers indicate the priorityof the likely cause of the problem

. Check each part in order. If necessary, replace these parts.

Release bearing (Worn, dirty or damaged)

Clutch pedal (Freeplay out of adjustment)

Diaphragm spring (Out of tip alignment)

Input shaft bearing (Worn or damaged)

Clutch disc torsion rubber (Damaged)

Clutch disc (Lack of spline grease)

Clutch disc (Runout is excessive)

Release cylinder cup (Damaged)

Master cylinder cup (Damaged)

Diaphragm spring (Damaged)

Clutch disc (Dirty or burred)

Clutch disc (Lining broken)

Engine mounting (Loosen)

Pressure plate (Distortion)

Clutch does not disengage

Clutch disc (Out of true)

Clutch line (Air in line)

Clutch disc (Worn out)

Clutch grabs/chatters

Flywheel (Distortion)

Clutch pedal spongy

Clutch disc (Harden)

Clutch disc (Oily)

Clutch noisy

Clutch slips P

arts Nam

e

See P

age

Trouble

MX-27

CL-14

CL-14

CL-13

CL-13

CL-16

CL-13

CL-13

CL-13

CL-13

CL-13

CL-13

CL-13

CL-13

CL-1 1

CL-8

CL-6

CL-5

-C

LUT

CH

TR

OU

BLE

SH

OO

TIN

GC

L-4

CLUTCH SYSTEM BLEEDINGHINT: If any work is done on the clutch system or if airis suspected in the clutch lines, bleed the system ofair.

NOTICE: Do not let brake fluid remain on a painted sur-face. Wash it off immediately.

1. FILL CLUTCH RESERVOIR WITH BRAKE FLUID2. CONNECT VINYL TUBE TO BLEEDER PLUGHINT: Check the reservoir frequently. Add fluid ifnecessary.Insert the other end of the tube in a half-full contain-er of brake fluid.3: BLEED CLUTCH LINE(a) Slowly pump the clutch pedal several times.(b) While pressing on the pedal, loosen the bleeder pluguntil the fluid starts to run out. Then close the bleederplug.SST 09023-00100(c) Repeat this procedure until there are no more airbubbles in the fluid.

-CLUTCH CLUTCH SYSTEM BLEEDINGCL-5

CLUTCH PEDALCLUTCH PEDAL CHECK AND ADJUSTMENT1. CHECK THAT PEDAL HEIGHT IS CORRECT

Pedal height from asphalt sheet:4-speed MX:144.5-154.5 mm (5.69-6.08 in.)5-speed MX:140.0-150.0 mm (5.51-5.91 in.)

2. IF NECESSARY, ADJUST PEDAL HEIGHTLoosen the lock nut and turn the stopper bolt until theheight is correct. Tighten the lock nut.3. CHECK THAT PEDAL FREEPLAY AND PUSH RODPLAY ARE CORRECT

Pedal freeplay:

Push in on the pedal until the beginning of clutchresistance is felt.

Pedal freeplay:5.0-15.0 mm (0.197-0.591 in.)Push rod play:

Push in on the pedal with a finger softly until theresistance 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 ANDPUSH ROD PLAY(a) Loosen the lock nut and turn the push rod until thefreeplay and push rod play are correct.(b) Tighten the lock nut.(c) After adjusting the pedal freeplay, check the pedalheight.(d) Connect the air duct and install the lower finish panel.5. INSPECT CLUTCH RELEASE POINT(a) Pull the parking brake lever and install wheel stopper.(b) Start the engine and idle the engine.(c) Without depressing the clutch pedal, slowly shift theshift lever into reverse position until the gears con-tact.

-CLUTCH CLUTCH PEDALCL-6

(d) Gradually depress the clutch pedal and measure thestroke 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 not as specified, perform the followingoperation.• Inspect pedal height.• Inspect push rod play and pedal freeplay.• Bleed the clutch line.• Inspect the clutch cover and disc.

6. CHECK CLUTCH START SYSTEM(a) Check that the engine does not start when the clutchpedal is released.(b) Check that the engine starts when the clutch pedal isfully depressed.If necessary, adjust or replace the clutch start switch.

7. CHECK CONTINUITY OF CLUTCH START SWITCH(a) Check that there is continuity between terminalswhen the switch is ON (pushed).(b) Check that there is no continuity between terminalswhen the switch is OFF (free).If continuity is not as specified, replace the switch.

-CLUTCH CLUTCH PEDALCL-7

MASTER CYLINDER REMOVAL1. DRAW OUT FLUID WITH SYRINGE2. DISCONNECT CLUTCH LINE TUBEUsing SST, disconnect the tube. Use a container tocatch the brake fluid.SST 09023-001003. REMOVE CLIP AND CLEVIS PIN4. REMOVE 2 MOUNTING NUTS AND PULL OUTMASTER CYLINDER

MASTER CYLINDER DISASSEMBLY1. REMOVE RESERVOIR TANK(a) Using a pin punch and a hammer, drive out the slottedspring pin.(b) Remove the reservoir tank and grommet.

CLUTCH MASTER CYLINDERCOMPONENTS

-CLUTCH CLUTCH MASTER CYLINDERCL-8

MASTER CYLINDER INSPECTIONHINT: Clean the disassembled parts with compressedair.1. INSPECT MASTER CYLINDER BORE FOR SCORINGOR CORROSIONIf a problem is found, clean or replace the cylinder.2. INSPECT PISTON AND CUPS FOR WEAR, SCORING,CRACKS OR SWELLINGIf either one requires replacement, use the parts fromthe cylinder kit.3. INSPECT PUSH ROD FOR WEAR OR DAMAGEIf necessary, replace the push rod.

MASTER CYLINDER ASSEMBLY1. COAT PARTS WITH LITHIUM SOAP BASE GLYCOLGREASE, AS SHOWN2. INSERT PISTON INTO CYLINDER3. INSTALL PUSH ROD ASSEMBLY WITH SNAP RING

4. INSTALL RESERVOIR TANK(a) Install the reservoir tank and new grommet.(b) Using a pin punch and a hammer, drive in the slottedspring pin.

2. REMOVE PUSH RODPull back the boot, and using snap ring pliers, removethe snap ring.3. REMOVE PISTON


MASTER CYLINDER INSTALLATION1. INSTALL MASTER CYLINDERInstall the 2 mounting nuts, and torque them.

Torque: 12 N-m (120 kgf-cm, 9 ft-lbf)

2. CONNECT CLUTCH LINE UNIONUsing SST, connect the union.SST 09023-00100


3. CONNECT PUSH ROD AND INSTALL PINInstall the clip in the push rod pin.4. BLEED SYSTEM AND ADJUST CLUTCH PEDAL(See page CL-5 , CL-6 )


RELEASE CYLINDER REMOVAL1. DISCONNECT CLUTCH LINE TUBEUsing SST, disconnect the tube. Use a container tocatch the brake fluid.SST 09023-001002. REMOVE 2 BOLTS AND PULL OUT RELEASE CYL-INDER

RELEASE CYLINDER DISASSEMBLY1. PULL OUT BOOT WITH PUSH ROD2. REMOVE PISTONUsing compressed air, remove the piston with thespring from the cylinder.

CLUTCH RELEASE CYLINDERCOMPONENTS

-CLUTCH CLUTCH RELEASE CYLINDERCL-1 1

RELEASE CYLINDER INSTALLATION1. INSTALL RELEASE CYLINDER WITH 2 BOLTS


2. CONNECT CLUTCH LINE TUBEUsing SST, connect the tube.SST 09023-00100


3. FILL CLUTCH RESERVOIR WITH BRAKE FLUIDAND BLEED CLUTCH SYSTEM(See page CL-5 )4. CHECK FOR LEAKS

RELEASE CYLINDER ASSEMBLY1. COAT PISTON WITH LITHIUM SOAP BASEGLYCOL GREASE, AS SHOWN2. INSTALL PISTON WITH SPRING INTO CYLINDER3. INSTALL BOOT WITH PUSH ROD TO CYLINDER

-CLUTCH CLUTCH RELEASE CYLINDERCL-12

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 springtension is released.(c) Remove the set bolts, and pull off the clutch coverwith the clutch disc.

NOTICE: Do not drop the clutch disc.

CLUTCH UNIT REMOVAL1. REMOVE TRANSAXLE FROM ENGINE(See MX section)

CLUTCH UNITCOMPONENTS

-CLUTCH CLUTCH UNITCL-13

4. INSPECT DIAPHRAGM SPRING FOR WEARUsing calipers, measure the diaphragm spring fordepth 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.

CLUTCH PARTS INSPECTION1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGEUsing calipers, measure the rivet head depth.

Minimum rivet depth:0.3 mm (0.012 in.)

If necessary, replace the clutch disc.

3. INSPECT FLYWHEEL RUNOUTUsing a dial indicator, check the flywheel runout.

Maximum runout:0.1 mm (0.004 in.)

If necessary, replace the flywheel.

2. INSPECT CLUTCH DISC RUNOUTUsing a dial indicator, check the disc runout.

Maximum runout:0.8 mm (0.031 in.)

If necessary, replace the clutch disc.

3. REMOVE RELEASE BEARING AND FORK FROMTRANSAXLERemove the release bearing together with the forkand then separate them.


5. INSPECT RELEASE BEARINGTurn the bearing by hand while applying force in theaxial direction.HINT: The bearing is permanently lubricated and re-quires no cleaning or lubrication.If necessary, replace the release bearing.

CLUTCH UNIT INSTALLATION1. INSTALL CLUTCH DISC AND CLUTCH COVER ONFLYWHEEL(a) Insert the SST in the clutch disc, and then set themand the clutch cover in position.SST 09301-32010

(b) Align the matchmarks on the clutch cover and fly-wheel.(c) Torque the bolts on the clutch cover in the ordershown.

Torque: 19 N-m (195 kgf-cm, 14 ft-Ibf)

HINT: Temporarily tighten the No.1 and No.2 bolts.

2. CHECK DIAPHRAGM SPRING TIP ALIGNMENTUsing a dial indicator with roller instrument, check thediaphragm spring tip alignment.

Maximum non-alignment:0.5 mm (0.020 in.)

If alignment is not as specified, using SST, adjust thediaphragm spring tip alignment.SST 09333-00013


3. APPLY MOLYBDENUM DISULPHIDE LITHIUMBASE GREASE (NLGI NO.2) TO FOLLOWING PARTS• Release fork and hub contact point• Release fork and push rod contact point• Release fork pivot point

4. INSTALL RELEASE BEARING AND FORK TO TRA-NSAXLEInstall the bearing to the release fork, and then installthem to the transaxle.

5. INSTALL TRANSAXLE TO ENGINE(See MX section)

• Clutch disc spline


SERVICE SPECIFICATIONSSERVICE DATA

Clutch release point from pedal full stroke end position

TORQUE SPECIFICATIONS

Pedal height from asphalt sheet (5-speed MX)

Pedal height from asphalt sheet (4-speed MX)

Diaphragm spring tip non -alignment (Maximum)

Diaphragm spring finger wear (Maximum width)

Diaphragm spring finger wear (Maximum depth)

140.0 -150.0 mm (5.51- 5.91 in.)

144.5 -154.5mm (5.69 -6.08in.)

Disc rivet head depth (Minimum)

5.0-15.0mm (0.197-0.591 in.)

Release cylinder installation bolt

1.0-5.0mm (0.039-0.197in.)

Master cylinder installation nut

Flywheel runout (Maximum)

Push rod play at pedal top

25mm (0.98in.) or more

Clutch cover x Flywheel

Disc runout (Maximum)

0.3mm (0.012in.)

0.1 mm (0.004in.)

0.8mm (0.031 in.)

5.0mm (0.197in.)

0.5mm (0.020in.)

0.6mm (0.024in.)

Flywheel set bolt

Clutch line union

Part tightened

Pedal freeplay

Bleeder plug 74 in.-lbf

kgf-cm ft-lbf

900

120

120

195

155

N-m

8.3

-CLUTCH SERVICE SPECIFICATIONSCL-17

Documents

Clutch de Toyota.pdf