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

4JA1-TC
ENGINE 6VE1 4JA1-T(L) C24SE
4JH1-TC
Clutch type Dry single plate with diaphragm
Size mm (in) 260 (10.24) 225 (8.86) 250 (9.84) 240 (9.45)
Clamping force kg(lb) 735 (1621) 500 (1103) 640 (1411) 560 (1235)
(N) (7200) (4900) (6300) (5500)
Pressure plate
Outside diameter mm(in) 260 (10.24) 225 (8.86) 250 (9.84) 240 (9.45)
Inside diameter mm(in) 170 (6.69) 150 (5.906) 160 (6.299) 160 (6.299)
Driven plate
Thickness mm(in)
at free 8.8 (0.346) 8.4 (0.331) 8.3 (0.327) 8.7 (0.342)
at compressed 8.2 (0.323) 7.8 (0.307) 7.8 (0.307) 8.0 (0.315)
Clutch Cont. type Hydraulic
Pedal free play mm(in) 5.0-15.0 (0.2-0.6)
Master cylinder
Bore´Stroke mm(in) 15.87 ´ 35 (0.625 ´ 1.38)
Slave cylinder
Bore ´ Stroke mm(in) 22.22 ´ 18.9 19.05 ´ 23 20.64 ´ 23 19.05 ´ 23
(0.875 ´ 0.744) (0.749 ´ 0.906) (0.813 ´ 0.906) (0.749 ´ 0.906)
 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 4.8/4T 7T 8.8 9.8/9T
Class Refined Non-Refined

Bolt Identifi-
cation

Bolt
´
Diameter´ -
Pitch (mm)

Standard Hex. M6 ´ 1.0 6 (0.6 / 52 lb.in) 7 (0.7 / 61 lb.in) 8 (0.8 / 69 lb.in) -

M8 ´ 1.25 13 (1.3 / 113 lb.in) 17 (1.7 / 12) 20 (2.0 / 14) 24 (2.4 / 17)
Head Bolt
M10 ´ 1.25 27 (2.8 / 20) 37 (3.8 / 27) 42 (4.3 / 31) 50 (5.1 / 37)
M12 ´ 1.25 61 (6.3 / 45) 76 (7.8 / 56) 87 (8.9 / 64) 95 (9.7 / 70)
M14 ´1.5 96 (9.8 / 71) 116 (11.8 / 85) 133 (13.6 / 98) 142 (14.5 / 105)
M16 ´ 1.5 130 (13.3 / 96) 170 (17.3 / 125) 193 (19.7 / 143) 200 (20.4 / 148)
M18 ´ 1.5 188 (19.2 / 139) 244 (24.9 / 180) 278 (28.3 / 205) 287 (29.3 / 212)
M20 ´ 1.5 258 (26.3 / 190) 337 (34.4 / 249) 385 (39.3 / 284) 396 (40.4 / 292)
M22 ´ 1.5 332 (33.9 / 245) 453 (46.3 / 335) 517 (52.7 / 381) 530 (54.1 / 391)
M24 ´ 2.0 449 (45.8 / 331) 570 (58.2 / 421) 651 (66.3 / 480) 692 (70.6 / 511)
* M10 ´ 1.5 26 (2.7 / 20) 36 (3.7 / 27) 41 (4.2 / 30) 48 (4.9 / 35)
* M12 ´ 1.75 57 (5.8 / 42) 71 (7.2 / 52) 80 (8.2 / 59) 89 (9.1 / 66)
* M14 ´ 2.0 89 (9.1 / 66) 110 (11.2 / 81) 125 (12.7 / 92) 133 (13.6 / 98)
* M16 ´ 2.0 124 (12.7 / 92) 162 (16.5 / 119) 185 (18.9 / 137) 191 (19.5 / 141)
Flange Bolt M6 ´ 1.0 7 (0.7 / 61 lb.in) 8 (0.8 / 69 lb.in) 9 (0.9 / 78 lb.in) -
M8 ´ 1.25 15 (1.5 / 11) 19 (1.9 / 14) 22 (2.2 / 16) 26 (2.7 / 20)
M10 ´ 1.25 31 (3.2 / 23) 41 (4.2 / 30) 47 (4.8 / 35) 56 (5.7 / 41)
M12 ´ 1.25 69 (7.0 / 51) 85 (8.7 / 63) 97 (9.9 / 72) 106 (10.8 / 78)
M14 ´ 1.5 104 (10.6 / 77) 126 (12.8 / 93) 144 (14.6 / 106) 154 (15.7 / 114)
M16 ´ 1.5 145 (14.8 / 127) 188 (19.2 / 139) 214 (21.8 / 158) 221 (22.5 / 163)
M18 ´ 1.5 - - - -
M20 ´ 1.5 - - - -
M22 ´ 1.5 - - - -
M24 ´ 2.0 - - - -
* M10 ´ 1.5 30 (3.1 / 22) 40 (4.1 / 30) 46 (4.7 / 34) 54 (5.5 / 40)
* M12 ´ 1.75 64 (6.5 / 47) 78 (8.0 / 58) 89 (9.1 / 66) 99 (10.1 / 73)
* M14 ´ 2.0 97 (9.9 / 72) 119 (12.1 / 88) 135 (13.8 / 99.7) 144 (14.7 / 107)
* M16 ´ 2.0 137 (14.0 / 101) 178 (18.2 / 132) 203 (20.7 / 132) 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) Torque N××m (kgf××m / lb ft) Pipe diameter mm (in) Torque N××m (kgf××m / lb ft)
4.76 (0.187) 16 (1.6 / 12) 10.00 (0.394) 54 (5.5 / 40)
6.35 (0.250) 26 (2.7 / 20) 12.00 (0.472) 88 (9.0 / 65)
8.00 (0.315) 44 (4.5 / 33) 15.00 (0.591) 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 6. Flywheel assembly and crank bearing
I 2. Pressure Plate assembly
I 3. Driven plate assembly Installation Steps
4. Release bearing To install, follow the removal steps in the
5. Shift fork 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 5-
8840-0007-0 (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 8.2 (0.323) 12 (0.472)
201R300011 4JA1T(L) 7.8 (0.307) 20 (0.787)
4JA1TC/
7.8 (0.307) 18 (0.71)
4JH1TC
C24SE 8.0 (0.315) 7.9 (0.311)
4. Note the pressure plate gauge reading.
Driven Plate Clamping Load N (kg/Ib)
Standard
6VE1 7200 (734/1618)
4JA1T(L) 5070 (517/1140)
4JA1TC/4JH1TC 6300 (642/1415)
C24SE 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
RTW37CSH000101 (11 - 22 lb) in direction of release, when clutch cover assembly
is bolted to the flywheel.
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 8.2 (0.323) 12 (0.472)
4JA1T(L) 7.8 (0.307) 20 (0.787)
4JA1TC/
7.8 (0.307) 18 (0.71)
4JH1TC
C24SE 8.0 (0.315) 7.9 (0.311)
Finger Height
6VE1 49.9-51.9 (1.96-2.04)
4JA1T(L) 31-33 (1.22-1.30)
4JA1TC/
39-41 (1.54-1.61)
4JH1TC
C24SE 39-41 (1.54-1.61)
 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
1.35-1.95 1.65-2.25 0.2
4J
(0.053-0.077) (0.065-0.089) (0.008)
6VE1 1.65-2.25 1.65-2.25 0.2
C24SE (0.065-0.089) (0.065-0.089) (0.008)
7C-32 CLUTCH

CLUTCH CONTROL
REMOVAL AND INSTALLATION

Removal Steps Installation Steps

1. Pin 8. Damper cylinder assembly
2. Jaw joint pin 7. Slave cylinder assembly
3. Pedal assembly 6. Oil line
4. Oil line 5. Master cylinder assembly
5. Master cylinder assembly 4. Oil line
6. Oil line 3. Pedal assembly
7. Slave cylinder assembly 2. Jaw joint pin
8. Damper cylinder assembly 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 4. Spring
2. Push rod 5. Cylinder body
3. Piston and piston cup

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. Clean the cylinder body and the piston.
2. Use an inside dial indicator to measure the cylinder bore.
3. Use a micrometer to measure the piston diameter.
4. 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 4. Push rod
2. Spring 5. Boot
I 3. Piston and piston cup

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 4. Spring
2. Push rod 5. Cylinder body
3. Piston and piston cup
 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

NG No push rod play in the master

Clutch pedal free play Adjust the push rod play
cylinder

OK

NG Insufficient grease on the front Clean and grease the release

Release bearing
cover contact surfaces bearing

NG Transmission front cover Repair or replace the

unevenly worn transmission front cover

OK

Grease or oil adhering to the NG Clean the related parts and/or

Too much grease
facing replace the facing

Clean the related parts and/or

NG Defective transmission front replace the facing
cover oil seal 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
Clean the related parts and/or
Grease or oil adhering to the NG Defective crankshaft rear oil replace the facing
facing seal Replace the crankshaft rear oil
seal

NG Release bearing broken Replace the release bearing

OK

NG Replace the driven plate

Facing Worn facing
assembly

OK

Clutch diaphragm spring NG Weak or broken clutch Replace the clutch pressure
diaphragm spring plate assembly
 CLUTCH 7C-45

2. CLUTCH DOES NOT RELEASE PROPERLY

Checkpoint Trouble Cause Countermeasure

NG Too much push rod play in the

Clutch pedal free play Adjust the push rod play
master cylinder

OK

NG
Hydraulic circuit Air in the hydraulic circuit Bleed the hydraulic circuit

OK

NG Driven plate warped or

Driven plate Replace the driven plate
unevenly worn

Insufficient grease on the

NG Clean and grease the splined
spline contact surface of the
contact surface
splined hub

Clean or repair the top gear

NG Corrosion or step wear on the shaft spline
top gear shaft spline Replace the top gear shaft

OK

NG Replace the pressure plate

Pressure plate Pressure plate unevenly worn
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

Replace the pilot bearing
causing pilot bearing wear
 CLUTCH 7C-47

3. CLUTCH SHUDDER

Checkpoint Trouble Cause Countermeasure

Poorly connected components Tighten the connections

NG
Power train causing looseness and Repair or replace the
abrasion applicable parts

OK

NG Replace the pressure plate

Pressure plate Pressure plate unevenly worn
assembly

OK

Grease or oil adhering to the NG Clean the related parts and/or

Too much grease
facing replace the facing

Clean the related parts and/or

NG Defective transmission front replace the facing
cover oil seal Replace the transmission front
cover oil seal

Clean the related parts and/or

NG Defective crankshaft rear oil replace the facing
seal Replace the crankshaft rear oil
seal
OK

Insufficient grease on the

NG spline contact surface of the Clean and grease the spline
Driven plate
splined hub contact surface

Clean or repair the top gear

NG Corrosion or step wear on the shaft spline
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 Replace the driven plate

Driven plate Loose facing rivets
assembly

NG Replace the driven plate

Warpage and/or uneven wear
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

NG Insufficient grease at the Clean and grease the pedal

Pedal shaft and sleeve
pedal shaft and sleeve shaft and sleeve

NG Worn pedal shaft and/or Replace the pedal shaft with

sleeve the sleeve

OK

Insufficient grease at the Clean and grease the master

Master cylinder piston and NG maser cylinder piston and cylinder piston and push rod
push rod contact faces
push rod contact faces contact faces

OK

Driven plate NG Loose or broken damper Replace the driven plate

spring assembly

OK

Insufficient grease at the

Crankshaft pilot bearing NG Replace the crankshaft pilot
crankshaft pilot bearing (pilot
bearing
bearing worn)

2) Clutch Pedal Not Depressed (Clutch Engaged)

Driven plate damper spring NG Weak or broken damper

Replace the driven plate
spring

OK

Insufficient grease at the

NG Replace the crankshaft pilot
Crankshaft pilot bearing crankshaft pilot bearing (pilot
bearing
bearing worn)
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 NG Loosely connected fluid pipe Tighten the fluid pipe and/or
hose and/or hose hose connections

OK

NG
Slave cylinder Weak or damaged piston cup Replace the piston cup

OK

NG
Slave cylinder oil pipe Loosely connected oil pipe Tighten the oil pipe connection

OK

NG
Fluid reservoir 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