OEM 2002 Toyota Tundra Clutch Disc

2002 Toyota Tundra Clutch Disc Parts Q&A

• Q: How to service and repair the clutch disc on 2002 Toyota Tundra?

  A: The clutch disc service and repair procedure begins with transmission engine detachment followed by clutch cover removal during which users should mark the components before loosening bolt sets one turn each until spring tension releases. Users should then remove the clutch disc without dropping it. Unfasten the boot and clutch release bearing along with the fork from the transmission by detaching their connection followed by removing the clip from the release bearing. First inspect the clutch disc by measuring the rivet head depth to confirm sufficient depth of at least 0.3 mm (0.012 inch); if the disc needs replacement get a new one. The clutch disc should undergo runout inspection through a dial indicator for values below 0.8 mm (0.031 inch). Similarly, the flywheel should be checked for runout that stays under 0.1 mm (0.004 inch). If the flywheel fails this criterion then it should be replaced immediately. Examine the pilot bearing by hand rotation and replace this component through the following process: remove opposite 2 bolts using Special Service Tool: 09303-35011 to extract the pilot bearing and replace it with a new one using Special Service Tool: 09304-30012 and a hammer until the pilot bearing shows smooth rotation before tightening the new bolts to 85 Nm (850 kgf-cm, 63 ft. lbs.). The maximum depth of the diaphragm spring should measure less than 0.6 mm (0.024 inch) while its width should not exceed 5.0 mm (0.197 inch) when performing this measurement. Obtain a new clutch cover for replacement purposes if necessary. The clutch release bearing must be checked with manual turning motions until replacement becomes necessary. To start installation the technician should use Special Service Tool: 09301-0110 and position it in the clutch disc before placing the matchmarks from the clutch cover and flywheel together while tightening all 6 bolts to 19 Nm (195 kgf-cm, 14 ft. lbs.) in the specified order for even distribution and proper disc centering. Use Special Service Tool: 09333-00013 to check diaphragm spring tip alignment through a dial indicator until maximum nonalignment stays below 0.5 mm (0.020 inch). Adjustments should be made as necessary. Release hub grease (Sealant: Part No. 08887-01806, release hub grease or equivalent) should be applied to both release fork and hub contact points after which clutch spline grease (Sealant: Part No. 08887-01706, clutch spline grease or equivalent) should be applied to the input shaft spline. The installation process requires the transmission to receive the boot and clutch release bearing and clutch release fork that should have their clip secured to the release bearing before reattaching the transmission to the engine.