WORKSHOP MANUAL

TF SERIES

CLUTCH

SECTION 7C

CLUTCH 7C-1

SECTION 7C

CLUTCH
TABLE OF CONTENTS
PAGE Main Data and Specifications ......................................................................................... 7C- 2 General Description......................................................................................................... 7C- 3 Torque Specification ....................................................................................................... 7C-15 Servicing........................................................................................................................... 7C-19 Clutch................................................................................................................................ 7C-21 Removal and Installation ............................................................................................ 7C-21 Inspection and Repair................................................................................................. 7C-26 Clutch Control.................................................................................................................. 7C-32 Removal and Installation ............................................................................................ 7C-32 Master Cylinder ................................................................................................................ 7C-33 Disassembly ................................................................................................................ 7C-33 Reassembly ................................................................................................................. 7C-34 Slave Cylinder (4J, C24SE) ............................................................................................. 7C-35 Disassembly ................................................................................................................ 7C-35 Inspection and Repair................................................................................................. 7C-36 Reassembly ................................................................................................................. 7C-37 Slave Cylinder (6VE1) ...................................................................................................... 7C-38 Disassembly ................................................................................................................ 7C-38 Inspection and Repair................................................................................................. 7C-39 Reassembly ................................................................................................................. 7C-40 Hydraulic Damper Cylinder............................................................................................. 7C-41 Inspection and Repair................................................................................................. 7C-41 Troubleshooting .............................................................................................................. 7C-42 Special Service Tool........................................................................................................ 7C-51

7C-2 CLUTCH

MAIN DATA AND SPECIFICATIONS

ENGINE Clutch type Size Clamping force Pressure plate Outside diameter Inside diameter Driven plate Thickness at free at compressed Clutch Cont. type Pedal free play Master cylinder Bore Stroke Slave cylinder Bore Stroke mm(in) 22.22 18.9 (0.875 0.744) 19.05 23 (0.749 0.906) 20.64 23 (0.813 0.906) 19.05 23 (0.749 0.906) mm(in) 15.87 35 (0.625 1.38) mm(in) mm(in) 8.8 (0.346) 8.2 (0.323) 8.4 (0.331) 7.8 (0.307) Hydraulic 5.0-15.0 (0.2-0.6) 8.3 (0.327) 7.8 (0.307) 8.7 (0.342) 8.0 (0.315) mm(in) mm(in) 260 (10.24) 170 (6.69) 225 (8.86) 150 (5.906) 250 (9.84) 160 (6.299) 240 (9.45) 160 (6.299) mm (in) kg(lb) (N) 260 (10.24) 735 (1621) (7200) 6VE1 4JA1-T(L) 4JA1-TC 4JH1-TC 250 (9.84) 640 (1411) (6300) C24SE

Dry single plate with diaphragm 225 (8.86) 500 (1103) (4900) 240 (9.45) 560 (1235) (5500)

CLUTCH 7C-3

GENERAL DESCRIPTION
HYDRAULIC CONTROL TYPE PUSH TYPE CLUTCH (4J C24SE)

PULL TYPE CLUTCH (6VE1)

A07RW046

7C-4 CLUTCH The clutch assembly consists of the pressure plate, the clutch cover, the diaphragm spring pivot pin and the driven plate assembly. The clutch pedal is connected to the release bearing through the shift fork. The driven plate assembly is installed between the flywheel and the pressure plate. For 4J series engine and HEC engine models, the push-type clutch is used. Diaphragm spring pressure holds the driven plate against flywheel and the pressure plate to provide the friction necessary to engage the clutch. Depressing the clutch pedal moves the shift fork against the release bearing. The release bearing forces the diaphragm to overcome the force of the diaphragm spring and separate the driven plate from the flywheel and pressure plate to disengage the clutch. For 6VE1 engine model, the pull-type clutch is used. The pull-type clutch is disengaged by pulling the release lever (release bearing) to disengage the pressure plate.

CLUTCH 7C-5

MASTER CYLINDER
C24SE/RHD

RTW47CSF000501

C24SE, 4J/LHD

RTW47CSF000201

7C-6 CLUTCH 6VE1/LHD

RTW47CSF000101

6VE1, 4J/RHD

RTW47CSF000401

The master cylinder converts mechanical energy into hydraulic energy. Depressing the clutch pedal causes the push rod to move against the piston to close the return port. Clutch fluid is forced out of the master cylinder. Releasing the clutch pedal causes the return spring to force the piston back to its original position. The return port is opened and the clutch fluid flows back into the fluid reservoir. Quickly releasing the clutch pedal will cause the fluid pressure at the return spring side to be lower than the fluid pressure at the push rod side. This allows the fluid at the push rod side to quickly flow to the return spring side through a port in the piston head. This equalizes the pressure at both sides of the piston.

CLUTCH 7C-7

SLAVE CYLINDER
6VE1

A07RS005

4J

C24SE

RTW47CSF000301

The slave cylinder converts hydraulic energy into mechanical energy. Hydraulic fluid supplied by the master cylinder moves the slave cylinder piston to actuate the shift fork. The mechanical energy produced by the slave cylinder is directly proportional to the diameters of the master cylinder and the slave cylinder. A bleeder screw is provided to bleed the slave cylinder.

7C-8 CLUTCH

HYDRAULIC DAMPER CYLINDER

RTW47CLF000101-X

The hydraulic damper cylinder is installed between the master cylinder and the slave cylinder to smooth out variations in clutch pedal feel.

CLUTCH 7C-9

PRESSURE PLATE ASSEMBLY

6VE1

A07RS006

7C-10 CLUTCH 4JA1T(L)

RTW47CMF000101

4JA1TC/4JH1TC

CLUTCH 7C-11 C24SE

RTW37CMF000101

The pressure plate assembly consists of the clutch cover, the pressure plate with diaphragm spring. Operating the clutch pedal causes the pressure plate to move in an axial direction to engage and disengage the clutch.

7C-12 CLUTCH

DRIVEN PLATE ASSEMBLY

6VE1

RTW37CMF000201

CLUTCH 7C-13 4JA1T(L)

RTW47CMF000401

4JA1TC/4JH1TC

7C-14 CLUTCH C24SE

RTW37CSF0003

The driven plate assembly consists of the plate and the facing. The plate consists of the clutch center, the cushioning plate and the torsion springs. The facing is riveted to both sides of the cushioning plate. The cushioning plate provides a longer service life by minimizing wear and vibration at the clutch contact surfaces.

CLUTCH 7C-15

TORQUE SPECIFICATION
STANDARD BOLTS
The torque values given in the following table should be applied where a particular torque is not specified. N m (kgf m/lb ft)
Strength Class Bolt Identification 4.8/4T 7T Refined 8.8 Non-Refined 9.8/9T

Bolt Diameter Pitch (mm) Standard Hex. Head Bolt M6 1.0 M8 1.25 M10 1.25 M12 1.25 M14 1.5 M16 1.5 M18 M20 M22 M24 * M10 * M12 * M14 * M16 Flange Bolt M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 * M10 * M12 * M14 * M16 1.5 1.5 1.5 2.0 1.5 1.75 2.0 2.0 1.0 1.25 1.25 1.25 1.5 1.5 1.5 1.5 1.5 2.0 1.5 1.75 2.0 2.0 6 (0.6 / 52 lb.in) 13 (1.3 / 113 lb.in) 27 (2.8 / 20) 61 (6.3 / 45) 96 (9.8 / 71) 130 (13.3 / 96) 188 (19.2 / 139) 258 (26.3 / 190) 332 (33.9 / 245) 449 (45.8 / 331) 26 (2.7 / 20) 57 (5.8 / 42) 89 (9.1 / 66) 124 (12.7 / 92) 7 (0.7 / 61 lb.in) 15 (1.5 / 11) 31 (3.2 / 23) 69 (7.0 / 51) 104 (10.6 / 77) 145 (14.8 / 127) 30 (3.1 / 22) 64 (6.5 / 47) 97 (9.9 / 72) 137 (14.0 / 101)

7 (0.7 / 61 lb.in) 17 (1.7 / 12) 37 (3.8 / 27) 76 (7.8 / 56) 116 (11.8 / 85) 170 (17.3 / 125) 244 (24.9 / 180) 337 (34.4 / 249) 453 (46.3 / 335) 570 (58.2 / 421) 36 (3.7 / 27) 71 (7.2 / 52) 110 (11.2 / 81) 162 (16.5 / 119) 8 (0.8 / 69 lb.in) 19 (1.9 / 14) 41 (4.2 / 30) 85 (8.7 / 63) 126 (12.8 / 93) 188 (19.2 / 139) 40 (4.1 / 30) 78 (8.0 / 58) 119 (12.1 / 88) 178 (18.2 / 132) 8 (0.8 / 69 lb.in) 20 (2.0 / 14) 42 (4.3 / 31) 87 (8.9 / 64) 133 (13.6 / 98) 193 (19.7 / 143) 278 (28.3 / 205) 385 (39.3 / 284) 517 (52.7 / 381) 651 (66.3 / 480) 41 (4.2 / 30) 80 (8.2 / 59) 125 (12.7 / 92) 185 (18.9 / 137) 9 (0.9 / 78 lb.in) 22 (2.2 / 16) 47 (4.8 / 35) 97 (9.9 / 72) 144 (14.6 / 106) 214 (21.8 / 158) 46 (4.7 / 34) 89 (9.1 / 66) 135 (13.8 / 99.7) 203 (20.7 / 132) 24 (2.4 / 17) 50 (5.1 / 37) 95 (9.7 / 70) 142 (14.5 / 105) 200 (20.4 / 148) 287 (29.3 / 212) 396 (40.4 / 292) 530 (54.1 / 391) 692 (70.6 / 511) 48 (4.9 / 35) 89 (9.1 / 66) 133 (13.6 / 98) 191 (19.5 / 141) 26 (2.7 / 20) 56 (5.7 / 41) 106 (10.8 / 78) 154 (15.7 / 114) 221 (22.5 / 163) 54 (5.5 / 40) 99 (10.1 / 73) 144 (14.7 / 107) 210 (21.5 / 155)

The asterisk * indicates that the bolts are used for female-threaded parts that are made of soft materials such as casting, etc.

FLARE NUTS
Pipe diameter mm (in) 4.76 (0.187) 6.35 (0.250) 8.00 (0.315) Torque N m (kgf m / lb ft) 16 (1.6 / 12) 26 (2.7 / 20) 44 (4.5 / 33) Pipe diameter mm (in) 10.00 (0.394) 12.00 (0.472) 15.00 (0.591) Torque N m (kgf m / lb ft) 54 (5.5 / 40) 88 (9.0 / 65) 106 (10.8 / 78)

7C-16 CLUTCH

TORQUE SPECIFICATIONS
N m (kgf m/lb ft)

CLUTCH 7C-17 6VE1, 4J N m (kgf m/lb ft)

RTW37CLF000401

7C-18 CLUTCH C24SE N m (kgf m/lb ft)

RTW37CLF000301

CLUTCH 7C-19

SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.

CLUTCH PEDAL PLAY

Inspection
Depress the clutch pedal lightly by hand, and measure to determine if the free play is within the standard value. Pedal Free Play mm(in) H 5.0-15.0 (0.2-0.6)

Adjustment of the clutch switch (or stopper bolt)

Turn the clutch switch or stopper bolt 1 until the switch bolt or stopper bolt just touches the clutch pedal arm. Adjust clutch switch or stopper bolt by backing it out half a turn, and measure the clearance (L) between the clutch pedal arm and the clutch switch bolt end or stopper bolt. Lock the lock nut 2 . Connect clutch switch connector. Clutch switch and clutch pedal Clearance mm(in) (L) 0.5-1.5 (0.020-0.059)

7C-20 CLUTCH

AIR BLEEDING
Bleed air from clutch operating cylinder according to the following procedure. Carefully monitor fluid level at master cylinder during bleeding operation. 1. Set the paking brake.

2. Top up reservoir with recommended brake fluid. 3. Connect a transparent vinyl tube to air bleeder valve.

4. Fully depress clutch pedal several times.

5. With clutch pedal depressed, open bleeder valve to release air. 6. Close bleeder valve. 7. Repeat steps 5 through 6 above until brake fluid flows from air bleeder valve without air bubbles. 8. Bleed air from clutch damper according to the above procedure. 9. Repeat the above bleeding procedure until the air completely removed.

CLUTCH 7C-21

CLUTCH
REMOVAL AND INSTALLATION

RTW37CLF000201-X

Removal Steps
1. Transmission assembly I 2. Pressure Plate assembly I 3. Driven plate assembly 4. Release bearing 5. Shift fork 6. Flywheel assembly and crank bearing

Installation Steps
To install, follow the removal steps in the reverse order.

7C-22 CLUTCH

Important Operations - Removal

1. Transmission Assembly Refer to MANUAL TRANSMISSION of section 7B and 7B1 for REMOVAL AND INSTALLATION procedure.

2. Clutch Pressure Plate Assembly 3. Driven Plate Assembly (1) Use the clutch pilot aligner 1 to prevent the driven plate assembly 2 from falling free. Clutch Pilot Aligner : 5-85253-001-0

4JH1-TC, C24SE

(2) Loosen the clutch cover bolts in the numerical order shown in the illustration. (3) Remove the pressure plate assembly 3 from the flywheel. (4) Remove the driven plate from the flywheel.

6VE1

201RS017

4. Release Bearing (6VE1) 5. Shift Fork (6VE1) (1) Remove the release bearing (1) from the transmission case. (2) Remove the shift fork snap pin (2). (3) Remove the shift fork pin and shift fork (3) from the fulcrum bridge.

220RW088-X

CLUTCH 7C-23 6. Flywheel Assembly and Crank Bearing (6VE1) (1) Remove flywheel assembly and crankshaft bearing. Do not remove except for replacement. (2) Use the remover 5-8840-2000-0 (J-5822) and sliding hammer 5-8840-0019-0 (J-23907) to remove the crankshaft bearing

015RW053

Important Operations - Installation

Follow the removal procedure in reverse order to perform the installation procedure. Pay careful attention to the important points during the installation procedure. 6. Flywheel Assembly and Crank Bearing (6VE1) (1) Install flywheel assembly and crankshaft bearing. Use the installer 5-8840-0125-0 (J-26516-A) and driver handle 58840-0007-0 (J-8092) to install the crankshaft bearing then clean and lubricate with grease.

015RW054

(2) Install new flywheel fixing bolts in the order illustrated and tighten them to the specified torque. N m (kg m/lb ft) 6VE1 54 (5.5/40) NOTE: Do not reuse the bolt and do not apply oil or thread lock to the bolt.

015RS047

7C-24 CLUTCH 5. Shift Fork (6VE1) 4. Release Bearing (6VE1) (1) Apply molybdenum disulfide type grease to the pin hole inner circumferences and thrust surfaces. (2) Attach the shift fork to the front cover and insert the pin from below of the front cover. (3) Install the washer and snap pin.

201RW019

(4) Apply molybdenum disulfide type grease to the areas shown in illustration.

201RW012

(5) Install the release bearing in the proper direction. NOTE: Ensure release bearing is properly positioned during installation, as shown in illustration.

201RW020

3. Driven plate Assembly 2. Clutch Pressure Plate Assembly (1) Clean the flywheel surface. (2) Clean the facing surface. (3) Use the clutch pilot aligner 1 to install the driven plate assembly 2 to the flywheel 3 . Clutch Pilot Aligner : 5-8525-3001-0

CLUTCH 7C-25
4JH1-TC, C24SE

(4) Clean the pressure plate surfaces. (5) Align the pressure plate assembly 4 with the flywheel knock pin 5 . (6) Install the pressure plate assembly to the flywheel. (7) Tighten the clutch cover bolts a little at a time in the numerical order shown in the illustration. Clutch Cover Bolt Torque N m (kgf m/lb ft) 18 3 (1.8 0.3 / 13.0 2.2)

6VE1

201RS017

(8) Remove the clutch pilot aligner. Note: Do not strike the clutch pilot aligner with a hammer to remove it.

7C-26 CLUTCH

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.

PRESSURE PLATE ASSEMBLY

Visually inspect the pressure plate friction surface for excessive wear and heat cracks. If excessive wear or deep heat cracks are present, the pressure plate must be replaced.

Pressure Plate Warpage

Use a straight edge and a feeler gauge to measure the pressure plate friction surface flatness in four directions. If any of the measured values exceed the specified limit, the pressure plate must be replaced. Pressure Plate Warpage mm(in) Limit 0.3 (0.012)

Clutch Cover
Visually inspect the entire clutch cover for excessive wear, cracking , and other damage. The clutch cover must be replaced if any of these conditions are present.

1. Abrasion, scratches, cracks and deflection of friction face to the disc, loose rivet and wear of ring Grind small scratches, or replace the assembly if extreme scratches are found.

CLUTCH 7C-27

Clutch Set Force

1. Invert the pressure plate assembly. 2. Place a metal sheet A on the pressure plate. 3. Compress the pressure plate assembly until the distance B becomes specified. Thickness and Distance mm(in) A B

6VE1
201R300011

8.2 (0.323) 7.8 (0.307) 7.8 (0.307) 8.0 (0.315)

12 (0.472) 20 (0.787) 18 (0.71) 7.9 (0.311)

N (kg/Ib)

4JA1T(L) 4JA1TC/ 4JH1TC C24SE

4. Note the pressure plate gauge reading. Driven Plate Clamping Load

Standard 6VE1 4JA1T(L) 4JA1TC/4JH1TC C24SE 7200 (734/1618) 5070 (517/1140) 6300 (642/1415) 5500 (561/1237)

Diaphragm Spring Finger Height

1. Place a new driven plate or the appropriate spacer beneath the pressure plate. 2. Fully compress the pressure plate and diaphragm spring. There are two ways to do this. Use a bench press to press down on the assembly from the top. Tighten the fixing bolts. NOTE: Preload on diaphragm spring finger must be 49 - 98 N (11 - 22 lb) in direction of release, when clutch cover assembly is bolted to the flywheel.

RTW37CSH000101

7C-28 CLUTCH 3. Measure the spring height from base to spring tip "H". If the measured value exceeds the specified limit, the pressure plate assembly must be replaced. Spacer Thickness mm(in) A B

6VE1 4JA1T(L) 4JA1TC/ 4JH1TC C24SE

Finger Height 6VE1

8.2 (0.323) 7.8 (0.307) 7.8 (0.307) 8.0 (0.315)

12 (0.472) 20 (0.787) 18 (0.71) 7.9 (0.311)

49.9-51.9 (1.96-2.04) 31-33 (1.22-1.30) 39-41 (1.54-1.61) 39-41 (1.54-1.61)

4JA1T(L) 4JA1TC/ 4JH1TC C24SE

CLUTCH 7C-29

Release Bearing (6VE1)

1. Visually check the release bearing for excessive play, noise and breakage. 2. If any of these conditions are discovered, the release bearing must be replaced.

201RS011

3. When replacing the release bearing (3), replace both the wedge collar (2) and wire ring (1) at the same time.

201RW010-X

Wedge Collar
1. Visually check the surfaces of the wedge collar making contact with the release bearing for excessive wear and damage. 2. Replace any exhibiting excessive wear or damage.

201RS013

Shift Fork
1. Visually check the surfaces of the shift fork making contact with the release bearing for excessive wear and damage. 2. Remove any minor stepping or abrasion from shift fork with an oil stone. 3. Replace any exhibiting excessive wear or damage.

201RS014

Release Bearing (4J, C24SE)

1. Visually inspect the surfaces of the release bearing making contact with the shift fork for excessive wear and damage. Replace any exhibiting excessive wear or damage. 2. Apply multi-purpose type grease (NLGI No.2 or No.3) to contact surface between the release bearing and the shift fork. (Do not apply grease to the sleeve inner face.)

7C-30 CLUTCH

Shift Fork
1. Visually inspect the surfaces of the shift fork making contact with the release bearing for excessive wear and damage. 2. Remove any minor stepping or abrasion from the release bearing with an oil stone. Replace any exhibiting excessive wear or damage. 3. Apply multi-purpose type grease (NLGI No.2 or No.3) to area.

DRIVEN PLATE ASSEMBLY

1. Visually inspect the torsion spring 1 for looseness, breakage, and weakening. If any of these conditions are discovered, the driven plate assembly must be replaced.

2. Visually inspect the facing surfaces 2 for cracking and excessive scorching. Visually inspect the facing surfaces for the presence of oil or grease. If any of these conditions are discovered, the facing must be cleaned or replaced.

3. Check that the driven plate moves smoothly on the transmission top gear shaft spline. Minor ridges on the top gear shaft spline may be removed with an oil stone.

Driven Plate Warpage

1. Insert the clutch pilot aligner into the driven plate splined hub. The clutch pilot aligner must be held perfectly horizontal. Clutch Pilot Aligner : 5-8525-3001-0 2. Set a dial indicator to the driven plate outside circumference. 3. Slowly turn the driven plate. Read the dial indicator as you turn the driven plate. If the measured value exceeds the specified limit, the driven plate assembly and/or the facing must be replaced. Driven Plate Warpage mm(in) Standard Limit

0.7 (0.028)

1.0 (0.039)

CLUTCH 7C-31

Driven Plate Splined Hub Spline Wear

1. Clean the driven plate splined hub. 2. Install the driven plate to the transmission top gear shaft spline. 3. Set a surface gauge to the driven plate outside circumference. 4. Slowly turn the driven plate counterclockwise. Measure the spline rotation play as you turn the driven plate. If the measured value exceeds the specified limit, the driven plate assembly must be replaced. Driven Plate Splined Hub Spline Wear mm(in) Standard Limit
0.5 (0.020) 1.0 (0.039)

Rivet Head Depression

Use a depth gauge or a straight edge with steel rule to measure the rivet head depression 1 from the facing surface 2. Be sure to measure the rivet head depression on both sides of the driven plate. If the measured value is less than the specified limit, the facing must be replaced. Rivet Head Depression mm(in) Standard Limit Fly wheel side P/Plate side

4J 6VE1 C24SE

1.35-1.95 (0.053-0.077) 1.65-2.25 (0.065-0.089)

1.65-2.25 (0.065-0.089) 1.65-2.25 (0.065-0.089)

0.2 (0.008) 0.2 (0.008)

7C-32 CLUTCH

CLUTCH CONTROL
REMOVAL AND INSTALLATION

Removal Steps
1. Pin 2. Jaw joint pin 3. Pedal assembly 4. Oil line 5. Master cylinder assembly 6. Oil line 7. Slave cylinder assembly 8. Damper cylinder assembly

Installation Steps
8. Damper cylinder assembly 7. Slave cylinder assembly 6. Oil line 5. Master cylinder assembly 4. Oil line 3. Pedal assembly 2. Jaw joint pin 1. Pin

CLUTCH 7C-33

MASTER CYLINDER
DISASSEMBLY

Disassembly Steps
1. Bolt : reservoir tank 2. Reservoir tank Comp 3. Yoke 4. Lock nut 5. Body sub assembly

7C-34 CLUTCH

REASSEMBLY

Reassembly Steps
1. Body sub assembly 2. Lock nut 3. Yoke 4. Reservoir tank Comp 5. Bolt : Reservoir Tank

CLUTCH 7C-35

SLAVE CYLINDER (4J, C24SE)

DISASSEMBLY

Disassembly Steps
I 1. Boot 2. Push rod 3. Piston and piston cup 4. Spring 5. Cylinder body

Important Operations
1. Boot Brake fluid spilled on painted or plastic surfaces will cause serious damage. Take care not to spill brake fluid.

7C-36 CLUTCH

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.

Cylinder Body
1. Clean the cylinder body. 2. Check the fluid return port for restrictions and clean it if necessary.

Cylinder Bore and piston Clearance

1. 2. 3. 4. Clean the cylinder body and the piston. Use an inside dial indicator to measure the cylinder bore. Use a micrometer to measure the piston diameter. Calculate the clearance between the cylinder bore and the piston diameter. If the clearance exceeds the limit, the entire slave cylinder assembly must be replaced. Cylinder Bore and Piston Clearance mm(in) Standard Limit

0.07 (0.0028)

0.15 (0.006)

Piston and Piston Cup

Visually inspect the disassembled piston and piston cup for excessive wear and damage. Replace the inner parts with new parts (Repair kit A) shown in the illustration.

CLUTCH 7C-37

REASSEMBLY

Reassembly Steps
I 1. Cylinder body 2. Spring I 3. Piston and piston cup 4. Push rod 5. Boot

Important Operations
1. Cylinder Body 1) Clean the cylinder body. 2) Apply brake fluid to the cylinder bore.

3. Piston and piston Cup 1) Apply brake fluid to the piston and piston cup. 2) Install the cups to the piston. Note the installation direction of the piston cups in the illustration. 3) Install the piston and piston cup to the cylinder body.

7C-38 CLUTCH

SLAVE CYLINDER (6VE1)

DISASSEMBLY

206RW004-X

Disassembly Steps
1. Boot 2. Push rod 3. Piston and piston cup 4. Spring 5. Cylinder body

CLUTCH 7C-39

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.

Cylinder Body
1. Clean the cylinder body. 2. Check the fluid return port for restrictions and clean it if necessary.

206RS003

Piston and Piston Cup

1. Visually inspect the disassembled piston and piston cup for excessive wear and damage. 2. Replace the inner parts with new parts shown in the illustration.

206RS004

3. Measure the clearance between slave cylinder wall and piston. 4. If the measured value exceeds the specified limit, the slave cylinder assembly must be replaced. mm(in) Standard Limit
0.07 (0.0028) 0.15 (0.006)

206RS005

7C-40 CLUTCH

REASSEMBLY
To reassemble, follow the disassembly steps in the reverse order, noting the following points:

1. Before installing the parts, apply a thin coat of rubber grease. 2. Install cup in groove in piston with the lip turned to the front of cylinder. Use care so as not to scratch the cylinder.

206RS006

CLUTCH 7C-41

HYDRAULIC DAMPER CYLINDER

INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.

Visually check for oil leakage and other damage. If oil leakage or other damage is discovered during the inspection; the damper cylinder assembly must be replaced as a unit.

7C-42 CLUTCH

TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair clutch problems. Each troubleshooting chart has three headings arranged from left to right. (1) checkpoint (2) Trouble Cause (3) Countermeasure This Section is divided into five sub-sections: 1. Clutch Slippage 2. Clutch Does Not Release Properly 3. Clutch Shudder 4. Clutch Noise 1) Clutch pedal Depressed (Clutch Disengaged) 2) Clutch pedal Not Depressed (Clutch Engaged) 5. Oil Leakage

CLUTCH 7C-43

1. CLUTCH SLIPPAGE
Checkpoint Trouble Cause Countermeasure

Clutch pedal free play

NG

No push rod play in the master cylinder

Adjust the push rod play

OK

Release bearing

NG

Insufficient grease on the front cover contact surfaces

Clean and grease the release bearing

NG

Transmission front cover unevenly worn

Repair or replace the transmission front cover

OK

Grease or oil adhering to the facing

NG

Too much grease

Clean the related parts and/or replace the facing

NG

Defective transmission front cover oil seal

Clean the related parts and/or replace the facing Replace the transmission front cover oil seal

OK

Continued on the next page

7C-44 CLUTCH Checkpoint Trouble Cause Countermeasure

Continued from the previous page OK Grease or oil adhering to the facing NG Defective crankshaft rear oil seal Clean the related parts and/or replace the facing Replace the crankshaft rear oil seal

NG OK

Release bearing broken

Replace the release bearing

Facing

NG

Worn facing

Replace the driven plate assembly

OK

Clutch diaphragm spring

NG

Weak or broken clutch diaphragm spring

Replace the clutch pressure plate assembly

CLUTCH 7C-45

2. CLUTCH DOES NOT RELEASE PROPERLY

Checkpoint Trouble Cause Countermeasure

Clutch pedal free play

NG

Too much push rod play in the master cylinder

Adjust the push rod play

OK

Hydraulic circuit

NG

Air in the hydraulic circuit

Bleed the hydraulic circuit

OK

Driven plate

NG

Driven plate warped or unevenly worn

Replace the driven plate

NG

Insufficient grease on the spline contact surface of the splined hub

Clean and grease the splined contact surface

NG

Corrosion or step wear on the top gear shaft spline

Clean or repair the top gear shaft spline Replace the top gear shaft

OK

Pressure plate

NG

Pressure plate unevenly worn

Replace the pressure plate assembly

OK

Continued on the next page

7C-46 CLUTCH Checkpoint Trouble Cause Countermeasure

Continued from the previous page OK NG

Flywheel

Flywheel unevenly worn

Repair or replace the flywheel

OK

Crankshaft pilot bearing

NG

Top gear shaft wobble is causing pilot bearing wear

Replace the pilot bearing

CLUTCH 7C-47

3. CLUTCH SHUDDER
Checkpoint Trouble Cause Poorly connected components causing looseness and abrasion Countermeasure Tighten the connections Repair or replace the applicable parts

Power train

NG

OK NG Replace the pressure plate assembly

Pressure plate

Pressure plate unevenly worn

OK NG Clean the related parts and/or replace the facing

Grease or oil adhering to the facing

Too much grease

NG

Defective transmission front cover oil seal

Clean the related parts and/or replace the facing Replace the transmission front cover oil seal

NG

Defective crankshaft rear oil seal

Clean the related parts and/or replace the facing Replace the crankshaft rear oil seal

OK

Driven plate

NG

Insufficient grease on the spline contact surface of the splined hub

Clean and grease the spline contact surface

NG

Corrosion or step wear on the top gear shaft spline

Clean or repair the top gear shaft spline Replace the top gear shaft

OK

Continued on the next page

7C-48 CLUTCH Checkpoint Trouble Cause Countermeasure

Continued from the previous page OK NG

Driven plate

Loose facing rivets

Replace the driven plate assembly

NG

Warpage and/or uneven wear

Replace the driven plate assembly

OK

Flywheel

NG

Flywheel uneven wear

Repair or replace the flywheel

CLUTCH 7C-49

4. CLUTCH NOISE
1) Clutch Pedal Depressed (Clutch Disengaged)
Checkpoint Trouble Cause Countermeasure

Pedal shaft and sleeve

NG

Insufficient grease at the pedal shaft and sleeve

Clean and grease the pedal shaft and sleeve

NG

Worn pedal shaft and/or sleeve

Replace the pedal shaft with the sleeve

OK Insufficient grease at the maser cylinder piston and push rod contact faces Clean and grease the master cylinder piston and push rod contact faces

Master cylinder piston and push rod contact faces

NG

OK

Driven plate

NG

Loose or broken damper spring

Replace the driven plate assembly

OK Insufficient grease at the crankshaft pilot bearing (pilot bearing worn)

Crankshaft pilot bearing

NG

Replace the crankshaft pilot bearing

2) Clutch Pedal Not Depressed (Clutch Engaged)

Driven plate damper spring

NG

Weak or broken damper spring

Replace the driven plate

OK Insufficient grease at the crankshaft pilot bearing (pilot bearing worn)

Crankshaft pilot bearing

NG

Replace the crankshaft pilot bearing

7C-50 CLUTCH

5. OIL LEAKAGE
Checkpoint Trouble Cause Countermeasure

Master cylinder

NG

Weak or damaged piston cup

Replace the body sub assembly

OK Master cylinder fluid pipe and hose NG Loosely connected fluid pipe and/or hose Tighten the fluid pipe and/or hose connections

OK

Slave cylinder

NG

Weak or damaged piston cup

Replace the piston cup

OK

Slave cylinder oil pipe

NG

Loosely connected oil pipe

Tighten the oil pipe connection

OK

Fluid reservoir

NG

Loosely connected oil pipe

Tighten the oil pipe

CLUTCH 7C-51

SPECIAL SERVICE TOOL

ITEM NO. ILLUSTRATION PART NO. PART NAME

5-85253-001-0

Clutch pilot aligner

7C-52 CLUTCH

MEMO

No. TFCLU-WE-0431