Clutch Unit: Inspection

WARNING: This page is about a different car, the 2004 Lexus IS 300. However, it is still accessible from the selected car via links, so may be relevant.

INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using vernier calipers, measure the rivet head depth.
1. Minimum rivet depth: 0.3 mm (0.012 in.)
If it is not as specified, replace the clutch disc.

Fig 1: Inspecting Clutch Disc For Wear Or Damage
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CLUTCH DISC RUNOUT
Using a dial indicator with roller instrument, check the disc runout.
1. Maximum runout: 0.8 mm (0.031 in.)
If it is not as specified, replace the clutch disc.

Fig 2: Inspecting Clutch Disc Runout
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FLYWHEEL RUNOUT
Using a dial indicator with roller instrument, check the flywheel runout.
1. Maximum runout: 0.1 mm (0.004 in.)
If it is not as specified, replace the flywheel.

Fig 3: Inspecting Flywheel Runout
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PILOT BEARING
Turn the bearing by hand while applying force in the axial direction.

If the bearing sticks or has much resistance, replace the pilot bearing.

Fig 4: Inspecting Pilot Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
IF NECESSARY, REPLACE PILOT BEARING
1. Remove the 2 bolts at diametrically opposite points.
  
  Fig 5: Removing Pilot Bearing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the pilot bearing.
  1. SST 09303-35011
  Fig 6: Removing Pilot Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a hammer, drive in a new pilot bearing.
  1. SST 09304-12012
  Fig 7: Installing Pilot Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 2 new bolts.
5. First, torque the 2 bolts uniformly a little at a time.
  1. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
6. Then tighten the 2 bolts and additional 80 - 100°.
Fig 8: Installing Pilot Bearing Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth and width of wear.

Fig 9: Inspecting Diaphragm Spring Depth & Width Of Wear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Maximum depth: A 0.6 mm (0.024 in.)
2. Maximum width: B 5.0 mm (0.197 in.)
If it is not as specified, replace the clutch cover.
INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial direction.

HINT:

The bearing is permanently lubricated and requires no cleaning or lubrication.

If necessary, replace the release bearing.

Fig 10: Inspecting Release Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002