Toyota 31250-33040 Disc Assembly, Clutch

Access to the clutch components is accomplished by removing the transaxle and engine assembly as a unit. Separate the transaxle from the engine, allowing the release fork (for 2009 and earlier models) and release bearing to remain attached to the transaxle temporarily. To support the clutch disc during removal, install a clutch alignment tool through the clutch disc hub. Carefully inspect the flywheel and pressure plate for indexing marks, which are usually an X, an O, or a white letter; if they cannot be found, scribe marks yourself to ensure proper alignment during installation. Slowly loosen the pressure plate-to-flywheel bolts in a diagonal pattern, relieving spring pressure before completely removing the bolts, followed by the pressure plate and clutch disc. When a problem occurs in the clutch, it is typically due to wear of the clutch driven plate assembly, but all components should be inspected. Check the flywheel for cracks, heat checking, score marks, and other damage; slight imperfections can be resurfaced. Inspect the lining on the clutch disc, ensuring at least 1/16-inch of lining above the rivet heads, and look for loose rivets, distortion, cracks, and broken springs. The release bearing should be replaced along with the clutch disc. Examine the pressure plate's machined surface and diaphragm spring fingers for score marks, cracks, and signs of overheating; replace the pressure plate assembly if damaged. Before installation, wipe the flywheel and pressure plate machined surfaces clean, ensuring no oil or grease is present. Position the clutch disc and pressure plate with the clutch held in place using an alignment tool, ensuring proper installation. Tighten the pressure plate-to-flywheel bolts only finger-tight, working around the pressure plate. Center the clutch disc by ensuring the alignment tool is through the splined hub and into the crankshaft recess, then tighten the bolts in a crisscross pattern to prevent distortion, finishing by tightening them to the specified torque and removing the alignment tool. Lubricate the inner groove of the release bearing with high-temperature grease, applying grease to the release lever contact areas and the transaxle input-shaft bearing retainer before installing the clutch release bearing. Finally, reinstall the transaxle and all previously removed components, tightening all fasteners to the proper torque specifications.

Engines are usually retained in the car and the transaxle is usually pulled to get access to the clutch components. In case the engine is pulled out for the major overhaul, it is recommended that the clutch should also be inspected for the worn out parts and replaced accordingly. Since getting to the clutch components is time consuming and may require a lot of effort, Singer suggests that during any engine or transaxle removal, the clutch components should be replaced although they are cheap. Specifically, the first thing to do is to take out the release cylinder but the hose attached must remain hanging arranged in a position that is out of the way. The transaxle has to be pulled out from the vehicle where the engine has to be properly supported perhaps with an engine hoist and one has to be much careful when removing the bolts on the oil pan. The release fork and bearing could still be permanently fixed on to the transaxle. There should be an alignment tool fitted through the clutch disc hub to help support the disc when it has to be removed. The flywheel and the pressure plate likewise should have their indexing marks checked; if none are present then new scribe marks should be made for use in aligning the two parts when re-fitting. The bolts that fasten pressure plate to the flywheel should be loosened in the cross-wise manner to allow spring tension be released before the pressure plate along with the clutch disc is removed. All other parts should also be checked for wear; flywheel for cracks and damages, clutch disc lining for thickness and any signs of damages, pressure plate for score marks and signs of overheating. This bearing should be also replaced along with the clutch disc as it will reach its wearing out point in the shortest time. Flies: before installed, the both surfaces of the flywheel and pressure plate must be free from oil and grease. Position clutch disc and pressure plate with the alignment tool to make sure that it is correctly placed. It is recommended that the pressure plate-to-flywheel bolts be tightened only until they are just barely snug in a manner that alternates between opposite bolts so that the flywheel doesn't get warped, then torqued to the correct amount. High-temperature grease should be applied to the inner groove of the release bearing and other contact part, then the release bearing should be placed in. Last but not least, the transaxle, release cylinder, and all the above-mentioned parts have to be refitted again and all fasteners have to be tightened to the specified torque.