Toyota Tacoma manuals

Toyota Corolla Repair Manual: Overhaul

1. Remove manual transaxle assy

2. Remove clutch release fork subassy

  1. Remove the clutch release fork with clutch release bearing from the transaxle assy.

3. Remove clutch release bearing assy

  1.  remove the clutch release bearing assy from the clutch release fork.

4. Remove release fork support

  1.  remove the release fork support from the transaxle assy.

5. Remove release bearing hub clip

6. Remove clutch release fork boot

7. Remove clutch cover assy

  1. Align the matchmarks on the clutch cover assy with the one on the flywheel subassy.
  2.  loosen each set bolt one turn at a time until spring tension is released.
  3.  remove the 6 bolts, and pull off the clutch cover assy.

Notice

: do not drop the clutch disc assy.

8. Remove clutch disc assy

Notice

: keep the lining part of the clutch disc assy, the pressure plate and surface of the flywheel subassy away from oil and foreign attachment.

9. Inspect clutch disc assy

  1. Using vernier calipers, measure the rivet head depth.

    Maximum rivet depth: 0.3 Mm (0.012 In.)

If necessary, replace the clutch disc assy.

  1.  install the clutch disc assy to the transaxle assy.

Notice

: take care not to insert the clutch disc assy in the wrong direction.

  1. Using a dial indicator, check the clutch disc assy runout.

    Minimum runout: 0.8 Mm (0.031 In.)

If necessary, replace the clutch disc assy.

10. Inspect clutch cover assy

  1. Using vernier calipers, inspect the diaphragm spring for depth and width of wear.

    Maximum:
    a (depth): 0.5 Mm (0.020 In.) B (width): 6.0 Mm (0.236 In.)

If necessary, replace clutch cover assy.

11. Inspect flywheel subassy

  1. Using a dial indicator, inspect the flywheel subassy runout.

    Maximum runout: 0.1 Mm (0.004 In.)

If necessary, replace the flywheel subassy.

12. Inspect clutch release bearing assy

  1. Turn the release 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 assy.

13. Install clutch disc assy

  1. Insert sst in the clutch disc assy, then insert them in the flywheel subassy.

    Sst 0930100210

Notice

: take care not to insert clutch disc assy in the wrong direction.

14. Install clutch cover assy

  1. Align the matchmarks on the clutch cover assy and flywheel subassy.
  2.  following the procedures shown in the illustration, tighten the 6 bolts, in the order starting the bolt locating near the knock pin on the top.

    Torque: 19.1 Nvm (195 Kgfcm, 14 ftlbf)

H

int

:

15. Inspect and adjust clutch cover assy

  1. Using a dial indicator with roller instrument, check the diaphragm spring tip alignment.

    Maximum nonalignment: 0.5 Mm (0.020 In.)

If alignment is not as specified, using sst, adjust the diaphragm spring tip alignment.

Sst 0933300013

16. Install release fork support

  1.  install the release fork support to the transaxle assy.

    Torque: 36.8 Nvm (375 Kgfcm, 27 ftlbf)

17. Install release bearing hub clip

18. Install clutch release fork subassy

  1. Apply release hub grease to the release fork and release bearing assy contact, release fork and push rod contact and release fork pivot points.

    Sealant:
    part no. 0888701806, Release hub grease or equivalent

  2.  install the release fork to the release bearing assy.

19. Install clutch release bearing assy

  1.  apply the clutch spline grease to the input shaft spline.

    Sealant: part no. 0888701706, Clutch spline grease or equivalent

  2.  install the bearing to the release fork, and then install them to the transaxle assy.

Notice

: after the installation, move the folk forward and backward to check that the release bearing slides smoothly.

20. Install clutch release fork boot

21. Install manual transaxle assy

Components
...

Clutch start switch assy (mtm)
...

Other materials:

Disposal
Hint: when scrapping vehicle equipped with an srs or disposing of a horn button assy, always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs in the airbag deployment, contact the service dept. Of toyota motor sales, u.S.A., Inc. Caution: ...

Power steering
Preparation Sst Recomended tools Equipment Lubricant Ssm ...

Problem symptoms table
Hint: if a normal code is displayed during the dtc check but the trouble still occurs, check the circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting. The matrix chart is divided into 3 chapters. If the instruc ...

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