OEM 2004 Toyota Matrix Clutch Disc

2004 Toyota Matrix Parts Questions & Experts Answers

• Q: How to overhaul the clutch disc on 2004 Toyota Matrix?

  A: The clutch disc repair process starts with manual transaxle removal and then requires the removal of clutch release components including the fork along with its bearing unit from the transaxle assembly. Remove the clutch release bearing assembly from the clutch release fork after which you should extract the transaxle assembly release fork support. Detach the release bearing hub clip along with the clutch release fork boot before you can remove the clutch cover assembly by matching the marks on the flywheel sub-assembly then relaxing spring tension by loosening each set bolt by one full turn until you can remove the six bolts to extract the cover assembly while avoiding dropping the clutch disc assembly. Before detachment of the clutch disc assembly keep the lining part as well as the pressure plate and flywheel sub-assembly surface free from oil and foreign materials. Vernier calipers should be used to examine the clutch disc assembly by measuring rivet head depth which must stay below 0.3 mm (0.012 inch) or require new clutch disc assembly replacement. Table 1 illustrates the installation procedure for the transaxle assembly. First insert the disc into its proper direction. Then use the dial indicator to check runout which should remain below 0.8 mm (0.031 inch); replace if necessary. Verify the diaphragm spring wear of the clutch cover assembly through vernier caliper measurements; the fixture depth must exceed 0.5 mm (0.020 inch) and width must exceed 6.0 mm (0.236 inch), but the assembly needs replacement in case of non-compliance. A dial indicator should be used to measure the flywheel sub-assembly runout which should be under 0.1 mm (0.004 inch); replace the part if this limit is exceeded. The clutch release bearing assembly should be checked by hand rotates while applying axial force so you can replace the release bearing assembly only when needed. For clutch disc assembly installation use Special Service Tool: 09301-00210 by properly placing it into the flywheel sub-assembly. First install Special Service Tool 09301-00210 by inserting it properly into the flywheel sub-assembly. Then use a torque wrench to tighten the six bolts starting with the one close to the knock pin to a torque of 19.1 Nm (195 kgf-cm, 14 ft. lbs.) while checking that the disc remains centered during the entire procedure. The clutch cover assembly requires inspection with a dial indicator for diaphragm spring tip alignment during which maximum non-alignment must not exceed 0.5 mm (0.020 inch). To adjust the assembly properly use Special Service Tool: 09333-00013. The transaxle assembly receives the release fork support which must be torqued to 36.8 Nm (375 kgf-cm, 27 ft. lbs.). The next step involves mounting the release bearing hub clip and clutch release fork sub-assembly during which time release hub grease (Part No. 08887-01806) should be applied to essential contact points. Before installation of the bearing onto the fork, the transaxle assembly and release fork must receive clutch spline grease (Part No. 08887-01706) on the input shaft spline. Then, check for smooth fork movement before final installation. Afterward install the clutch release fork boot together with the manual transaxle assembly.