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    Clutch Unit2

    Uploaded by

    Cristiano Bruschini
    The document provides instructions for overhauling a clutch unit on a manual transaxle assembly. The steps include: 1. Removing the manual transaxle assembly. 2. Removing the clutch release fork sub-assembly, clutch release bearing assembly, release fork support, release bearing hub clip and clutch release fork boot. 3. Removing the clutch cover assembly by aligning matchmarks and loosening bolts. 4. Inspecting the clutch disc assembly, clutch cover assembly, flywheel sub-assembly and clutch release bearing assembly. 5. Reinstalling components in reverse order, applying specified greases and torques.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Clutch Unit2

    Uploaded by

    Cristiano Bruschini
    165 views4 pages
    The document provides instructions for overhauling a clutch unit on a manual transaxle assembly. The steps include: 1. Removing the manual transaxle assembly. 2. Removing the clutch release fork sub-assembly, clutch release bearing assembly, release fork support, release bearing hub clip and clutch release fork boot. 3. Removing the clutch cover assembly by aligning matchmarks and loosening bolts. 4. Inspecting the clutch disc assembly, clutch cover assembly, flywheel sub-assembly and clutch release bearing assembly. 5. Reinstalling components in reverse order, applying specified greases and torques.

    Original Description:

    Clutch Unit2

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    The document provides instructions for overhauling a clutch unit on a manual transaxle assembly. The steps include: 1. Removing the manual transaxle assembly. 2. Removing the clutch release fork sub-assembly, clutch release bearing assembly, release fork support, release bearing hub clip and clutch release fork boot. 3. Removing the clutch cover assembly by aligning matchmarks and loosening bolts. 4. Inspecting the clutch disc assembly, clutch cover assembly, flywheel sub-assembly and clutch release bearing assembly. 5. Reinstalling components in reverse order, applying specified greases and torques.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    165 views4 pages

    Clutch Unit2

    Uploaded by

    Cristiano Bruschini
    The document provides instructions for overhauling a clutch unit on a manual transaxle assembly. The steps include: 1. Removing the manual transaxle assembly. 2. Removing the clutch release fork sub-assembly, clutch release bearing assembly, release fork support, release bearing hub clip and clutch release fork boot. 3. Removing the clutch cover assembly by aligning matchmarks and loosening bolts. 4. Inspecting the clutch disc assembly, clutch cover assembly, flywheel sub-assembly and clutch release bearing assembly. 5. Reinstalling components in reverse order, applying specified greases and torques.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 4

    4218

    CLUTCH

    CLUTCH UNIT (MTM)


    4203T01

    OVERHAUL
    1.

    REMOVE MANUAL TRANSAXLE ASSY (See page 4117)

    2.
    (a)

    REMOVE CLUTCH RELEASE FORK SUBASSY


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

    Q01056

    3.
    (a)
    4.
    (a)
    5.
    6.

    REMOVE CLUTCH RELEASE BEARING ASSY


    Remove the clutch release bearing assy from the clutch release fork.
    REMOVE RELEASE FORK SUPPORT
    Remove the release fork support from the transaxle assy.
    REMOVE RELEASE BEARING HUB CLIP
    REMOVE CLUTCH RELEASE FORK BOOT

    7.
    (a)

    C62955

    REMOVE CLUTCH COVER ASSY


    Align the matchmarks on the clutch cover assy with the
    one on the flywheel subassy.
    (b) Loosen each set bolt one turn at a time until spring tension
    is released.
    (c) Remove the 6 bolts, and pull off the clutch cover assy.
    NOTICE:
    Do not drop the clutch disc assy.
    Matchmarks

    D25280

    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.
    (a)

    INSPECT CLUTCH DISC ASSY


    Using vernier calipers, measure the rivet head depth.
    Maximum rivet depth: 0.3 mm (0.012 in.)
    If necessary, replace the clutch disc assy.
    (b) Install the clutch disc assy to the transaxle assy.
    NOTICE:
    Take care not to insert the clutch disc assy in the wrong
    direction.
    C62956

    2004 COROLLA (RM1037U)

    Author:

    Date:

    1515

    4219
    CLUTCH

    CLUTCH UNIT (MTM)

    (c)
    Transaxle
    Side

    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.

    D26338

    10.
    (a)

    INSPECT CLUTCH COVER ASSY


    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.

    C57466
    D25281

    11.
    (a)

    INSPECT FLYWHEEL SUBASSY


    Using a dial indicator, inspect the flywheel subassy runout.
    Maximum runout: 0.1 mm (0.004 in.)
    If necessary, replace the flywheel subassy.

    C62958

    12.
    (a)

    INSPECT CLUTCH RELEASE BEARING ASSY


    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.
    Q01060

    13.
    (a)

    INSTALL CLUTCH DISC ASSY


    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.

    Flywheel Side

    SST
    D26339

    2004 COROLLA (RM1037U)

    Author:

    Date:

    1516

    4220
    CLUTCH

    SST

    1 (Temporally), 4

    14.
    (a)
    (b)

    6
    5
    2

    CLUTCH UNIT (MTM)

    INSTALL CLUTCH COVER ASSY


    Align the matchmarks on the clutch cover assy and flywheel subassy.
    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 Nm (195 kgfcm, 14 ftlbf)

    HINT:

    Matchmarks
    D26323

    
    

    Following the order in the illustration, tighten the bolts at


    a time evenly.
    Move SST up and down, right and left lightly, after checking that the disc is in the center, tighten the bolts.

    15.
    (a)

    INSPECT AND ADJUST CLUTCH COVER ASSY


    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

    SST

    D00205

    16.
    (a)
    17.

    INSTALL RELEASE FORK SUPPORT


    Install the release fork support to the transaxle assy.
    Torque: 36.8 Nm (375 kgfcm, 27 ftlbf)
    INSTALL RELEASE BEARING HUB CLIP
    18.
    (a)

    (b)
    Release hub grease

    INSTALL CLUTCH RELEASE FORK SUBASSY


    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
    Install the release fork to the release bearing assy.

    D27398

    19.
    (a)

    INSTALL CLUTCH RELEASE BEARING ASSY


    Apply the clutch spline grease to the input shaft spline.
    Sealant:
    Part No. 0888701706, CLUTCH SPLINE GREASE or equivalent
    (b) 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.

    2004 COROLLA (RM1037U)

    Author:

    Date:

    1517

    4221
    CLUTCH

    20.
    21.

    CLUTCH UNIT (MTM)

    INSTALL CLUTCH RELEASE FORK BOOT


    INSTALL MANUAL TRANSAXLE ASSY (See page 4117)

    2004 COROLLA (RM1037U)

    Author:

    Date:

    1518

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