Toyota 31250-05101
Disc

The overhaul procedure for clutch disc begins with manual transaxle assembly disassembly and then the removal of clutch release fork sub-assembly containing clutch release fork and bearing. The clutch release bearing assembly needs to be broken free from the fork to remove the release fork support from the transaxle assembly. The clutch cover assembly can be detached by centering the matchmarks from the flywheel sub-assembly. Loosen one set of bolts at a time to relieve spring tension until you can remove the six bolts and pull away the clutch cover assembly without letting the clutch disc assembly fall. You should remove the clutch disc assembly while maintaining a clear surface on its lining and pressure plate and flywheel to prevent contamination by oil or foreign materials. Vernier calipers must be used to measure the rivet head depth in the clutch disc assembly and diagnose an excessive reading beyond 0.3 mm (0.012 inch). In such a case, the assembly requires immediate replacement. After proper direction insertion of the clutch disc assembly into the transaxle assembly check its runout using a dial indicator to confirm less than 0.8 mm (0.031 inch) deviation. Replace if runout exceeds the limit. Measure the diaphragm spring wear of the clutch cover assembly with vernier calipers to ensure both depth remains below 0.5 mm (0.020 inch) and width remains less than 6.0 mm (0.236 inch). Change the assembly when necessary. Test the flywheel sub-assembly runout by using a dial indicator to verify it is below 0.1 mm (0.004 inch) because replacement is needed if this value is exceeded. Turn the clutch release bearing assembly manually under axial pressure then change the component if needed. Special Service Tool 09301-00210 should be used to install the clutch disc assembly following correct orientation. Position the matchmarks from both the clutch cover assembly and flywheel sub-assembly before tightening the six bolts to 19.1 Nm (195 kgf-cm, 14 ft. lbs.) at specified torque sequence maintaining uniform clamp load and verifying disc position. Check diaphragm spring tip alignment of the clutch cover assembly with a dial indicator. This alignment should not exceed 0.5 mm (0.020 inch) maximum non-alignment but if needed adjust it using Special Service Tool: 09333-00013. To install the release fork support join the transaxle assembly at 36.8 Nm (375 kgf-cm, 27 ft. lbs.) beforeInstalling the release bearing hub clip and clutch release fork sub-assembly with an application of release hub grease (Part No. 08887-01806) to essential contact areas. The installation requires clutch spline grease (Part No. 08887-01706) on the input shaft spline before putting the bearing into the release fork which leads to the transaxle assembly resulting in proper release fork movement. The manual transaxle assembly and clutch release fork boot need installation as the final steps.

Start clutch disc service and repair by first taking out the manual transaxle assembly then removing the clutch release fork sub-assembly containing the removal of clutch release fork together with clutch release bearing from the transaxle assembly. The service begins with removing the clutch release bearing assembly from the clutch release fork before extracting the release fork support from the transaxle assembly followed by the release bearing hub clip and clutch release fork boot. Begin to remove the clutch cover assembly by lining up the matchmarks of clutch cover and flywheel sub-assembly while loosening all set bolts one round at a time until spring tension frees up. Afterward remove the 6 bolts to extract the clutch cover assembly maintaining the clutch disc assembly from falling. You should disassemble the clutch disc assembly while maintaining the oil-free state of the pressure plate as well as the lining part of the clutch disc assembly and the flywheel sub-assembly surface. You need to inspect the clutch disc assembly rivet head depth with vernier calippers to check if it exceeds 0.3 mm (0.012 in.). If not, replace it. Put the clutch disc assembly into the transaxle assembly along the correct installation path and verify its straightness with a dial indicator that should not show more than 0.8 mm (0.032 in.) deviation. Check the clutch cover assembly for wear and verify the diaphragm spring depth meets 0.5 mm (0.020 in.) while the width should be 6.0 mm (0.236 in.) to warrant a replacement. A dial indicator should measure the flywheel sub-assembly runout and maintain a reading below 0.1 mm (0.004 in.) while the clutch release bearing assembly needs inspection for damage and wear and its operation needs replacement if needed. You can install Special Service Tool: 09301-00210 by inserting it first into the clutch disc assembly and then into the flywheel sub-assembly but maintain correct orientation during this process. Tighten 6 bolts between the clutch cover assembly and flywheel sub-assembly following the specified order to 19 Nm (195 kgf/cm, 14 ft. lbs.) while confirming disc centering through even tension. Check the diaphragm spring tip alignment of the clutch cover assembly using a dial indicator with roller instrument by adjusting it with Special Service Tool: 09333-00013 when necessary. Socialize the release fork by affixing it to the transaxle assembly at a torque of 37 Nm (375 kgf/cm, 27 ft. lbs.). Subsequently attach the release bearing hub clip after which the technician should attach the clutch release fork sub-assembly and apply Toyota Genuine Release Hub Grease or equivalent to key contact points. Before implementing the clutch release bearing to the transaxle assembly users need to apply Toyota Genuine Clutch Spline Grease or equivalent to input shaft spline followed by checking smooth operation of the release bearing after installation. You must install both the manual transaxle assembly and the clutch release fork boot at the end of the process.

Check diaphragm spring tip alignment with a dial indicator, ensuring maximum non-alignment does not exceed 0.5 mm (0.020 inch); adjust if necessary using Special Service Tool: 09333-00013.

Torque to 36.8 Nm (375 kgf-cm, 27 ft. lbs.).