Clutch Unit: Removal

REMOVE MANUAL TRANSAXLE ASSEMBLY
1. Remove the transaxle ( REMOVAL ).
REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY
1. Remove the clutch release fork with the clutch release bearing from the transaxle.
REMOVE CLUTCH RELEASE BEARING ASSEMBLY
1. Remove the clutch release bearing from the clutch release fork.
REMOVE RELEASE BEARING HUB CLIP
REMOVE CLUTCH RELEASE FORK BOOT
REMOVE RELEASE FORK SUPPORT
1. Remove the release fork support from the transaxle.
  
  Fig 1: Identifying Clutch Release Bearing From Clutch Release Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CLUTCH COVER ASSEMBLY
1. Put matchmark on the clutch cover and flywheel.
2. Loosen each set bolt one turn at a time until spring tension is released.
3. Remove the set bolts, and pull off the clutch cover.
  NOTE: Do not drop the clutch disc.
REMOVE CLUTCH DISC ASSEMBLY
NOTE: Keep the lining part of the clutch disc, the pressure plate and surface of the flywheel away from oil and foreign matter.

Fig 2: Identifying Matchmark On Clutch Cover And Flywheel
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CLUTCH DISC ASSEMBLY
1. Using a vernier caliper, measure the rivet head depth.
  Minimum rivet depth: 0.3 mm (0.012 in.)
  
  If the depth is less than the minimum, replace the clutch disc assembly.
2. Install the clutch disc to the transaxle.
  NOTE: Take care not to insert the clutch disc assembly in the wrong direction.
  
  Fig 3: Identifying Rivet Head Depth
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a dial indicator, measure the clutch disc runout.
  Maximum runout: 0.8 mm (0.031 in.)
  
  If the runout is greater than the maximum, replace the clutch disc assembly.
  
  Fig 4: Identifying Clutch Disc Runout
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CLUTCH COVER ASSEMBLY
1. Using a vernier caliper, measure the diaphragm spring for the depth and width of wear.
  Maximum wear:
  
  A (Depth): 0.5 mm (0.020 in.)
  
  B (Width): 6.0 mm (0.236 in.)
  
  If the wear is greater than the maximum, replace the clutch cover assembly.
  
  Fig 5: Identifying Diaphragm Spring For Depth And Width Of Wear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FLYWHEEL SUB-ASSEMBLY
1. Using a dial indicator, measure the flywheel runout.
  Maximum runout: 0.1 mm (0.004 in.)
  
  If the runout is greater than the maximum, replace the flywheel sub-assembly.
  
  Fig 6: Identifying Flywheel Runout
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CLUTCH RELEASE BEARING ASSEMBLY
1. Check that the clutch release bearing assembly moves smoothly without abnormal resistance by turning the sliding parts of the clutch release bearing (contact surfaces with the clutch cover) while applying force in the axial direction.
2. Inspect the clutch release bearing for damage or wear.
  HINT:
  
  If necessary, replace the release bearing assembly.
  
  Fig 7: Identifying Clutch Release Bearing Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002