Toyota 31210-05043
Pressure Plate

Starting the pressure plate overhaul requires steps including manual transaxle assembly removal and subsequent clutch release fork sub-assembly extraction followed by the clutch release fork separation with its clutch release bearing from the transaxle assembly. Start by taking out the clutch release bearing assembly from the clutch release fork followed by removing the release fork support from the transaxle assembly then continuing with removal of the release bearing hub clip before taking the clutch release fork boot. Align the matchmarks from the clutch cover assembly on the flywheel sub-assembly before loosening each set bolt one turn to free up spring tension. Remove the clutch cover assembly after removing its six bolts and keep the clutch disc assembly from falling during removal. Remove the clutch disc assembly while maintaining the lining part of the clutch disc assembly together with the pressure plate and surface of the flywheel sub-assembly free from oil and all foreign substances. Vernier calipers must measure rivet head depth in the clutch disc assembly to ensure it stays under 0.3 mm (0.012 inch); if needed, replace the assembly. The correct direction insertion of the clutch disc assembly into the transaxle assembly demands measurement with a dial indicator to confirm runout below 0.8 mm (0.031 inch). If the runout reaches beyond 0.8 mm it requires replacement. Vernier calipers should be used to examine the clutch cover assembly, which requires diaphragm spring depth to remain below 0.5 mm (0.020 inch) and width to stay within 6.0 mm (0.236 inch); replace failed components. A dial indicator should be used to inspect flywheel sub-assembly runout which must be below 0.1 mm (0.004 inch) otherwise replacement is required. The clutch release bearing assembly should be checked by hand turning with axial loading until replacement becomes necessary. The installation requires using Special Service Tool: 09301-00210 to enter the clutch disc assembly before guiding it into the flywheel sub-assembly with the correct orientation. Follow the matchmark alignment while tightening the specified bolt order to 19.1 Nm (195 kgf-cm, 14 ft. lbs.) and check that the disc stays centered during this process. Use the dial indicator with roller instrument to check diaphragm spring tip alignment on the clutch cover assembly during inspection and adjustment until it reaches within 0.5 mm (0.020 inch); Special Service Tool: 09333-00013 helps with any required adjustments. The installation order begins with the clamp support of the support assembly to the transaxle assembly at 36.8 Nm (375 kgf-cm, 27 ft. lbs.) torque followed by the bearing hub release clip and the clutch release fork sub-assembly. Release hub grease (Part No. 08887-01806) is essential for each contact point before assembly. Pre-installation requires the input shaft spline to receive clutch spline grease (Part No. 08887-01706) then verify the release bearing shows smooth movement before completing the installation. The manual transaxle assembly should be put together after installing the clutch release fork boot.

The first step in pressure plate overhauling requires manual transaxle assembly removal then clutch release fork sub-assembly dismantling and clutch release fork extraction together with clutch release bearing from the transaxle assembly. The maintenance of the clutch release fork begins by removing the clutch release bearing assembly from the clutch release fork. Subsequently, remove the release fork support from the transaxle assembly followed by the release bearing hub clip and clutch release fork boot. Reach the clutch cover assembly after correctly aligning its matchmarks with flywheel sub-assembly marks. Then loosen each bolt set once while monitoring spring tension before extracting all 6 bolts to remove the clutch cover assembly without dropping the clutch disc assembly. Continue by taking out the clutch disc assembly without applying oil or foreign objects to the lining part and pressure plate and surface of the flywheel sub-assembly. Use vernier calipers to check the depth of clutch disc assembly rivets which should not exceed 0.3 mm (0.012 inch); if necessary replace the assembly before reinstalling into the correct direction of the transaxle. To check the clutch disc assembly runout, use a dial indicator which should show results less than 0.8 mm (0.031 inch). Replace the clutch disc assembly if required. Vernier calipers show the clutch cover assembly has proper diaphragm spring depth and width of wear when the depth exceeds 0.5 mm (0.020 inch) and the width reaches 6.0 mm (0.236 inch); when this maintenance criteria is not met the clutch cover assembly requires replacement. Check the flywheel sub-assembly runout using a dial indicator and replace it if the measurement exceeds 0.1 mm (0.004 inch). A hand examination of the clutch release bearing for axial force requires replacement of the bearing assembly if necessary. Use Special Service Tool: 09301-00210 to install the clutch disc assembly while ensuring proper direction insert before fitting the clutch cover assembly which requires matching marks along with 6 bolt tightening at 19.1 Nm (195 kgf-cm, 14 ft. lbs.) torque and disc position verification. The clutch cover assembly should undergo inspection and adjustment by using Special Service Tool: 09333-00013 along with a dial indicator to check the diaphragm spring tip alignment; maximum non-alignment must stay below 0.5 mm (0.020 inch). Users must install the transaxle assembly support which receives a torque of 36.8 Nm (375 kgf-cm, 27 ft. lbs.) followed by installation of the release bearing hub clip along with the clutch release fork sub-assembly where release hub grease (Part No. 08887-01806) must be applied before installing the release fork to the release bearing assembly. Clutch spline grease (Part No. 08887-01706) should be applied to the input shaft spline and the bearing installation on the release fork must follow before installing them to the transaxle assembly. Check that the release bearing moves without resistance after completing installation. Completion of the installation process includes insertion of the clutch release fork boot along with the manual transaxle assembly.

Clutch spline grease (Part No. 08887-01706).