Toyota 31250-12360-84
Disc

The procedure to remove the clutch disc starts with detaching the transaxle from the engine followed by selecting the matchmarks on the clutch cover and flywheel before slowly rotating the set bolts until spring tension dissipates then sliding off the clutch cover accompanied by the clutch disc while maintaining clutch disc position to avoid dropping it. Begin by taking the release bearing and fork as one piece before disconnecting them and finally removing the release fork support and boot. The clutch disc requires replacement if the vernier caliper measurement reveals rivet head depth below 0.3 mm (0.012 inch). Use a dial indicator to check the clutch disc runout and it must be lower than 0.8 mm (0.031 inch). Additionally measure the flywheel runout using the same tool which should not exceed 0.1 mm (0.004 inch), or obtain a new flywheel if necessary. The diaphragm spring requires inspection for deterioration based on two parameters: maximum depth allowance of 0.5 mm (0.020 inch) and width limit of 6.0 mm (0.236 inch). If either limit is exceeded it is necessary to replace the clutch cover. A hand-operated checking of the release bearing combined with applied axial force can reveal a need for replacement. To install the clutch system use Special Service Tool: 09301-00210 by placing it on the clutch disc before positioning it onto the flywheel in the correct direction then align the matchmarks between clutch cover and flywheel and tighten the 6 bolts in sequence to 19 Nm (195 kgf-cm, 14 ft. lbs.) torque with uniform tension to confirm disc centering. The alignment of diaphragm spring tips must be checked with a dial indicator to ensure 0.5 mm (0.020 inch) maximum distance between points. If any misalignment exists Special Service Tool: 09333-00013 is needed to adjust the position. The process includes applying torque of 37 Nm (375 kgf-cm, 27 ft. lbs.) to secure the boot and release fork support at the transaxle. At this point use Part No. 08887-01806 release hub grease to coat contact points between the fork and hub and Part No. 08887-01706 clutch spline grease must be applied to the input shaft spline. Install the transaxle to the engine after installing its release bearing along with the fork and completing all necessary steps.

Servicing or repairing clutch disc requires steps to begin with removing the transaxle from the engine followed by aligning the matchmarks before slowly loosening set bolts until spring tension is released then finishing by removing set bolts to extract clutch cover along with clutch disc and taking care to avoid letting the clutch disc fall. The service requires first removal of the connected release bearing and fork followed by their separation before removing the release fork support and boot. Examine the clutch disc through vernier caliper measurement of rivet head depth to ensure it maintains at least 0.3 mm (0.012 inch), otherwise replace it with a new unit. Examine the clutch disc runout using a dial indicator and maintain a maximum limit of 0.8 mm (0.031 inch) while testing the flywheel runout for its maximum limit of 0.1 mm (0.004 inch) before replacing the damaged flywheel. Follow a two-step tightening procedure for the flywheel bolts starting at 49 Nm torque (500 kgf-cm / 36 ft. lbs.) and marking the bolts before retightening them by 90 degrees. Check the diaphragm spring's condition using vernier calipers to measure its depth and width before replacing the clutch cover because the depth should not exceed 0.5 mm (0.020 inch) and the width should not exceed 6.0 mm (0.236 inch). An inspection of the release bearing for replacement should be performed by rotating it manually under axial stress. Note that this bearing has permanent lubrication. The installation process requires Special Service Tool: 09301-00210 that should be inserted first into the clutch disc before being placed into the flywheel while ensuring the clutch disc is installed correctly. Position the matchmarks on the clutch cover and flywheel. Tighten the six bolts while following the specified installation order until they reach 19 Nm (195 kgf-cm, 14 ft. lbs.) while maintaining even distribution and confirming disk centering. Verify the alignment of the diaphragm spring tips with Special Service Tool: 09333-00013 by using a dial indicator. Maintain maximum non-alignment below 0.5 mm (0.020 inch), adjust as needed to meet the specifications. The transaxle receives the boot and release fork support at 37 Nm (375 kgf-cm, 27 ft. lbs.) using Special Service Tool 08887-01806 for release fork and hub contact. Add Special Service Tool 08887-01706 to input shaft spline. Finished installation requires the transaxle to receive the release bearing, fork and its reinstallation to the engine.

The procedure starts with engine transaxle removal followed by clutch cover and disc extraction when you properly line up clutch cover and flywheel matchmarks while loosening clamping bolts one turn until spring tension releases before drawing the cover and disc out. During this process do not let the clutch disc fall. The service starts by removing the release bearing and fork as one piece before separating them and continuing with the removal of release fork support along with boot. The clutch disc requires inspection using calipers to measure its rivet head depth which should be at least 0.3 mm (0.012 inch). If the measurement falls short, replace the clutch disc. A dial indicator helps check the clutch disc's runout until it reaches 0.8 mm (0.031 inch) while the flywheel runout should not exceed 0.1 mm (0.004 inch) before performing necessary replacements. Measure the diaphragm spring for wear to verify its maximum depth is 0.5 mm (0.020 inch) and maximum width is 6.0 mm (0.236 inch). Then consider replacing the clutch cover if necessary. The inspection includes manual turning of the release bearing with axial loading for determining its replacement needs. The installation process starts with placing Special Service Tool: 09301-00210 on the flywheel but ensuring the clutch disc points towards the correct direction. Then center the matchmarks between both clutch cover and flywheel before tightening the 6 bolts in the sequence to 19 Nm (195 kgf-cm, 14 ft. lbs.), checking for even distribution and disc centering. Follow these steps to check the diaphragm spring tip alignment using a dial indicator until measurement stays below 0.5 mm (0.020 inch). If this measurement is exceeded, use Special Service Tool: 09333-00013 for adjustment. The boot and release fork support needs to be fastened to the transaxle with a torque of 37 Nm (375 kgf-cm, 27 ft. lbs.) Follow this step by spreading molybdenum disulphide lithium base grease (NLGI NO. 2) to the release fork contact points alongside the bearing as well as the push rod and clutch spline. Use product 08887-01706 (100g) of recommended grease to lubricate the release fork and bearing contact points and push rod contact point and pivot point and clutch spline. Reinstall the transaxle with the assembly of the release bearing and fork installed to the transaxle unit.

The clutch disc overhaul sequence begins with manual transaxle assembly extraction and continues with the removal of the clutch release fork sub-assembly that requires dismantling of the clutch release fork with its clutch release bearing from the transaxle assembly. The next step is to remove the clutch release bearing assembly from the clutch release fork and afterward extract the release fork support from the transaxle assembly together with the release bearing hub clip and the clutch release fork boot. Starting from matchmarks, loosen each set bolt gradually with one turn until spring tension releases so you can remove the 6 bolts that detach the clutch cover assembly to avoid dropping the clutch disc assembly. The technician will separate the clutch disc assembly while also maintaining a clean condition for its lining part along with the pressure plate and flywheel sub-assembly surface. Use vernier calipers to check the depth of clutch disc assembly rivet heads which must be less than 0.3 mm (0.012 inch) for proper operation or replace the assembly. You must install the clutch disc assembly into the transaxle assembly with accurate direction before verifying its runout with a dial indicator until it reaches 0.8 mm (0.031 inch) for necessary replacement. To check diaphragm spring wear within the clutch cover assembly use a vernier caliper then inspect both the depth which must be minimum 0.5 mm (0.020 inch) and the width that needs to measure 6.0 mm (0.236 inch); do a replacement when necessary. A dial indicator should be used to check the flywheel sub-assembly runout to ensure it does not exceed 0.1 mm (0.004 inch) since replacement will be required if this value is exceeded. Testing the clutch release bearing assembly with hand movement under axial force conditions requires a replacement of the assembly if necessary. Use Special Service Tool: 09301-00210 to install the clutch disc assembly before installing it into the flywheel sub-assembly with the correct orientation. Position the clutch cover assembly according to matchmarks before applying torque to 19.1 Nm (195 kgf-cm, 14 ft. lbs.) to the specified 6 bolts in the right sequence while verifying that the disc remains centered. Use a dial indicator to check the diaphragm spring tip alignment in the clutch cover assembly while inspecting the maximum non-alignment distance; this distance should not exceed 0.5 mm (0.020 inch). Adjust the assembly with Special Service Tool: 09333-00013 if necessary. Installation of the release fork support to the transaxle assembly requires torque 36.8 Nm followed by installing the release bearing hub clip and clutch release fork sub-assembly. Release hub grease (Part No. 08887-01806) must be applied to specified contact points before each component gets installed. The clutch spline grease (Part No. 08887-01706) should be applied to the input shaft spline before installing the clutch release bearing assembly. Make sure the release bearing moves easily during installation. Place the clutch release fork boot and the manual transaxle assembly as the last stage of installation.

The clutch disc repair process begins by extracting the transaxle from the engine followed by clutch cover and disc removal through matching bolt marks on the flywheel and clutch cover. Each bolt needs a gradual turn until the spring tension releases then a careful clutch disc extraction follows to prevent dropping of the clutch disc. Unfasten the release bearing and fork unit before splitting them apart while taking off both the release fork support and boot. Use a vernier caliper to measure the clutch disc head rivet depth because a depth less than 0.3 mm (0.012 inch) justifies disc replacement. Use a dial indicator to measure the clutch disc runout because excessive runout should not surpass 0.8 mm (0.031 inch). Additionally, check the flywheel runout that must not exceed 0.1 mm (0.004 inch) and conduct a replacement if necessary. The diaphragm spring evaluation should include measurements of depth which must not surpass 0.5 mm (0.020 inch) and width measurements which must not exceed 6.0 mm (0.236 inch); new clutch cover installation may be necessary. Manual turning of the release bearing requires an applied axial force to inspect for wear; replace the bearing if any wear signs appear. To complete the installation position Special Service Tool: 09301-00210 onto the clutch disc by placing it on the flywheel while making sure the clutch disc does not face the wrong direction next check the matchmarks on both the clutch cover and the flywheel align and tighten the 6 bolts in order according to the specified torque of 19 Nm (195 kgf-cm, 14 ft. lbs.). Also verify an even bolt tension and proper clutch disc centering. Use dial indicator Special Service Tool: 09333-00013 to check the diaphragm spring tip alignment until it shows 0.5 mm or less (0.020 inch); adjust this alignment if necessary. The transaxle receives the boot and release fork support installation before technicians apply release hub grease (Part No. 08887-01806 or equivalent) to the release fork and hub contact along with release fork and push rod contact and release fork pivot points. The input shaft spline requires clutch spline grease (Part No. 08887-01706 or equivalent). Position the release bearing together with the fork onto the transaxle before reinstalling the transaxle onto the engine assembly.

Ensure the fork moves smoothly after installation.