Toyota 31210-20380 Cover Assembly, Clutch

The clutch parts are usually accessed with the transaxle of the vehicle in place, although the engine remains a part of the car. In case of a major overhaul of the engine then the clutch should also be checked for signs of wear and expectedly repairing or replacing damaged parts is best done at this stage since parts of the clutch are relatively cheaper than the time it would take to access the clutch. The following procedures are based on assumed that the engine stays in the car. Start by sliding the release cylinder back and ensure it is out of the way but do not detach the hose. Subsequently, take out the transaxle from the car and make sure that the engine is effectively supported and maybe with an engine lift or support stand. If using a jack place a piece of wood between the jack and the oil pan and be careful as the oil pump pick up is towards the end of the pan and may distort the pan and lead to oil starvation. It is acceptable to leave the release fork and bearing connected to the transaxle for a while longer. For clamping support of the clutch disc, screw in a clutch alignment tool through the disc hub. Search the surface of the flywheel as well as the pressure plate for signs of indexing and in the absence of such signs, make them yourself once you are to reassemble the unit. Lose the pressure plate to the flywheel bolts diagonally, in order to ease the tension of the clutch spring, then take the bolts, then the pressure plate, as well as the clutch disc. While inspecting the engine components, examine the flywheel for presence of any crack or any defect on its surface and it should be corrected by resurfacing if there is any. For the clutch disc lining, see that they are worn by at most 1/32-inch above the rivet heads and appear for any damage. Products like the release bearing should be replaced together with the clutch disc. Check pressures of the pressure plate for signs of wear or damage, if worn replace the pressure plate. Several new shells about flywheel and pressure plate: Before the installation the machined surfaces of the flywheel and pressure plate have to be free of oil and grease. Insert the clutch disc on the flywheel with the help of an alignment tool and make sure that the pressure plate is installed in the correct manner. Now again tighten the pressure plate-to-flywheel bolts up to just 'snug' fit, align the clutch disc and then in a cross-hatch sequence tighten these bolts and finally use a torque wrench on them. In the inner groove of the release bearing as well as around the contact surfaces of the release lever and the input shaft bearing retainer apply HTL. The next step is to bolt in the clutch release bearing, the transaxle and the back in the components that were previously removed: everything must be tightened to the recommended torque.

Clutch components may be accessed by removing the transaxle, but the engine should not be removed unless it is being overhauled. In these cases, worn clutch components should be checked and replaced because their cost of replacement is much less than that of laborious access to them. Start with the release cylinder removal without hose disconnection when the engine remains in situ. After this, extract the transaxle out of the car providing assistance to the motor during removal either through an engine hoist or a jack under the engine with a piece of wood placed beneath to spread out loads. For now, keep the release bearing and release fork on the transaxle. To ease clutch disc removal, put a clutch alignment tool through its hub. Check for indexing marks on both flywheel and pressure plate; if they are missing, make scribe marks as guides for installation later on. Gradually loosen up bolts that hold together pressure plate and flywheel in a diagonal manner to relieve spring pressure and then take out bolts followed by pressure plate and clutch disc. Examine flywheel for any damage, so as to decide whether slight imperfections should be machined out at a machine shop. Evaluate thickness of clutch disc lining along with rivet condition and any signs of damage that might necessitate its replacement. Install new clutch discs alongside release bearings. Inspect machined surface of pressure plate as well as diaphragm spring fingers for any damages which can necessitate replacing entire assembly; you can remove minor glazing using emery cloth however. They do provide factory rebuilt units whenever getting another stock pressure plate is called for. Prior to installation, ensure oil-free surfaces on clean flywheels, pres-sure plates,and clutch discs handling them with clean hands all throughout. Place an alignment tool between the clutch disc and pressure plate before finger tightening bolts around it (Flynn & Rushing). Guide the alignment tool into position centralizing clutch disc between pressure plate bolts, and then tighten the bolts down in a crossover pattern to the specified torque. Take out alignment tool, apply high temperature grease onto inner groove of release bearing as well as contact areas of release lever and insert grease inside input-shaft bearing retainer from transaxle. Proceed to reinstall all of the following: clutch release bearing; transaxle; release cylinder; and every part previously taken off with all fasteners tightened to recommended torque specifications.