Question 1

How to overhaul the pressure plate on Toyota Corolla?

Accepted Answer

Starting the pressure plate overhaul requires steps including manual transaxle assembly removal and subsequent clutch release fork sub-assembly extraction followed by the clutch release fork separation with its clutch release bearing from the transaxle assembly. Start by taking out the clutch release bearing assembly from the clutch release fork followed by removing the release fork support from the transaxle assembly then continuing with removal of the release bearing hub clip before taking the clutch release fork boot. Align the matchmarks from the clutch cover assembly on the flywheel sub-assembly before loosening each set bolt one turn to free up spring tension. Remove the clutch cover assembly after removing its six bolts and keep the clutch disc assembly from falling during removal. Remove the clutch disc assembly while maintaining the lining part of the clutch disc assembly together with the pressure plate and surface of the flywheel sub-assembly free from oil and all foreign substances. Vernier calipers must measure rivet head depth in the clutch disc assembly to ensure it stays under 0.3 mm (0.012 inch); if needed, replace the assembly. The correct direction insertion of the clutch disc assembly into the transaxle assembly demands measurement with a dial indicator to confirm runout below 0.8 mm (0.031 inch). If the runout reaches beyond 0.8 mm it requires replacement. Vernier calipers should be used to examine the clutch cover assembly, which requires diaphragm spring depth to remain below 0.5 mm (0.020 inch) and width to stay within 6.0 mm (0.236 inch); replace failed components. A dial indicator should be used to inspect flywheel sub-assembly runout which must be below 0.1 mm (0.004 inch) otherwise replacement is required. The clutch release bearing assembly should be checked by hand turning with axial loading until replacement becomes necessary. The installation requires using Special Service Tool: 09301-00210 to enter the clutch disc assembly before guiding it into the flywheel sub-assembly with the correct orientation. Follow the matchmark alignment while tightening the specified bolt order to 19.1 Nm (195 kgf-cm, 14 ft. lbs.) and check that the disc stays centered during this process. Use the dial indicator with roller instrument to check diaphragm spring tip alignment on the clutch cover assembly during inspection and adjustment until it reaches within 0.5 mm (0.020 inch); Special Service Tool: 09333-00013 helps with any required adjustments. The installation order begins with the clamp support of the support assembly to the transaxle assembly at 36.8 Nm (375 kgf-cm, 27 ft. lbs.) torque followed by the bearing hub release clip and the clutch release fork sub-assembly. Release hub grease (Part No. 08887-01806) is essential for each contact point before assembly. Pre-installation requires the input shaft spline to receive clutch spline grease (Part No. 08887-01706) then verify the release bearing shows smooth movement before completing the installation. The manual transaxle assembly should be put together after installing the clutch release fork boot.

Question 2

How to overhaul the pressure plate on Toyota Matrix?

Accepted Answer

The pressure plate overhaul process begins with removal of manual transaxle components and then proceeds with the sequential removal of clutch release fork sub-assembly before extracting the fork and bearing from the transaxle assembly. Begin the process by removing the clutch release bearing assembly from the clutch release fork before moving to the release fork support from transaxle assembly and afterward taking off the release bearing hub clip and clutch release fork boot. Use a socket wrench to line up the matchmarks while untightening each bolt gradually until the spring tension frees, then remove the 6 bolt to disconnect the clutch cover assembly without letting the clutch disc assembly fall. After removing the clutch disc assembly maintain a clean status for the lining part and pressure plate and flywheel sub-assembly surface surface free from oil and foreign objects. Measure the distance of the rivet heads on the clutch disc assembly with vernier calipers to verify it stays below 0.3 mm (0.012 inch) before continuing; replace the clutch disc assembly if needed. Install the clutch disc assembly into the transaxle assembly while facing it in the right direction and run it through a dial indicator which should read less than 0.8 mm (0.031 inch) at most; replace if this limit is exceeded. Verify the clutch cover assembly diaphragm spring wear with vernier calipers to confirm both depth exceeds 0.5 mm (0.020 inch) and width exceeds 6.0 mm (0.236 inch); perform a replacement if necessary. A dial indicator must check the flywheel sub-assembly runout which should not exceed 0.1 mm (0.004 inch). Replace the component if required. To check the clutch release bearing assembly function properly turn it by hand under axial force conditions; perform a replacement of the release bearing assembly if required. Install the clutch disc assembly through Special Service Tool: 09301-00210 which should go first into the clutch disc assembly then into the flywheel sub-assembly while maintaining proper orientation. Install the clutch cover assembly by aligning the matchmarks before tightening the bolts in a specified order up to 19.1 Nm (195 kgf-cm, 14 ft. lbs.) torque while checking for disc centering. To inspect and adjust clutch cover assembly so diaphragm spring tip alignment can be checked with a dial indicator for maximum non-alignment of less than 0.5 mm (0.020 inch), Special Service Tool: 09333-00013 should be used to conduct any necessary adjustments. The transaxle assembly should receive the release fork support which requires 36.8 Nm (375 kgf-cm, 27 ft. lbs.) torques while the clutch release fork sub-assembly installation must be accompanied by application of release hub grease (Part No. 08887-01806) at contact points. Before installation of the clutch release bearing assembly you must apply clutch spline grease (Part No. 08887-01706) to the input shaft spline. Also verify that the release bearing slides easily once installed. End the installation process by installing both the clutch release fork boot together with the manual transaxle.

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Toyota Pressure Plate

Toyota Pressure Plate

Toyota Pressure Plate

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Toyota Pressure Plate

Toyota Pressure Plate

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Toyota Pressure Plate

Toyota Pressure Plate

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Toyota Pressure Plate

Toyota Pressure Plate

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