How to overhaul the clutch disc on Toyota Camry?

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The overhaul process for the clutch disc starts with manual transaxle assembly removal followed by disassembly of the clutch release fork boot, clutch release bearing assembly, clutch release fork sub-assembly and release bearing hub clip and release fork support. Start by matching marks on the clutch cover assembly to the flywheel sub-assembly. After that loosen set bolts by one turn at a time to release spring tension before removing set bolts and pulling off the clutch cover assembly while avoiding dropping the clutch disc assembly. The clutch disc assembly needs removal after which maintain the lining part as well as pressure plate and surface of the flywheel sub-assembly completely free from oil and foreign attachments. The clutch disc assembly needs inspection with vernier calipers to check rivet head depth against a maximum of 0.3 mm (0.012 inch). If the depth exceeds this threshold, the clutch disc assembly requires replacement. Place the clutch disc assembly into the transaxle assembly with proper installation direction and check its runout with the dial indicator because excessive 0.8 mm (0.031 inch) runout requires replacement. A traditional caliper measurement must be performed to evaluate clutch cover assembly diaphragm spring wear. The measurement depth should be below 0.5 mm (0.020 inch) and the width should be under 6.0 mm (0.236 inch); replacement is needed when either measurement exceeds these limits. A dial indicator should be used to check flywheel sub-assembly runout which must stay below 0.1 mm (0.004 inch) or require replacement. A hand operation of the clutch release bearing assembly needs axial force checks before replacement if required. Install the clutch disc assembly by inserting Special Service Tool: 09301-00220 so it fits into both the clutch disc assembly and the flywheel sub-assembly in the correct direction. Reinstall the clutch cover assembly after securing the six bolts to a torque of 19.1 Nm (199 kgf-cm, 14 ft. lbs.) while matching all the bolts' points and verifying the disc remains directly in the clutch center. The procedure to check and adjust clutch cover assembly requires the use of Special Service Tool: 09333-00013 for diaphragm spring tip alignment inspection with a dial indicator to confirm maximum non-alignment stays under 0.5 mm (0.020 inch). Those working on the installation should install the manual transaxle release fork support by applying 47.1 Nm (480 kgf-cm, 35 ft. lbs.) torque and then connect the release bearing hub clip to the assembly. Apply Part No. 08887-01806 RELEASE HUB GREASE or equivalent to points where the release fork contacts the release bearing assembly before installing the release fork to the bearing assembly. The input shaft requires clutch spline grease (Part No. 08887-01706, CLUTCH SPLINE GREASE or equivalent) before installing the release fork with release bearing assembly to the manual transaxle assembly. Make sure the release bearing moves without resistance after installation. At the conclusion of assembly you must add the clutch release fork boot and manual transaxle assembly.

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