CL−11

CLUTCH − CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER

COMPONENTS

MASTER CYLINDER REMOVAL

1. DRAW OUT FLUID WITH SYRINGE
2. REMOVE PUSH ROD PIN
3. DISCONNECT CLUTCH LINE UNION
Using SST, disconnect the union nut.
SST 09023−00100
4. REMOVE MASTER CYLINDER
(a) Remove the mounting nut.
(b) Pull out the master cylinder.

MASTER CYLINDER DISASSEMBLY

1. REMOVE RESERVOIR TANK
(a) Using a pin punch and hammer, drive out the slotted spring
pin.
(b) Remove reservoir tank and grommet.
CL−12
CLUTCH − CLUTCH MASTER CYLINDER

2. REMOVE PUSH ROD

(a) Pull back the boot and, using snap ring pliers, remove the
snap ring.
(b) Pull out the push rod and washer.
(c) Remove the piston from the cylinder.

MASTER CYLINDER INSPECTION

HINT: Clean the disassembled parts with compressed air.
1. INSPECT MASTER CYLINDER BORE FOR SCORING OR
CORROSION
If a problem is found, clean or replace the cylinder.
2. INSPECT PISTON AND CUPS FOR WEAR, SCORING,
CRACKS OR SWELLING
If either one requires replacement, use the parts from the cyl-
inder kit.
3. INSPECT PUSH ROD FOR WEAR OR DAMAGE
If necessary, replace the push rod.

MASTER CYLINDER ASSEMBLY

1. COAT PARTS WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
2. INSERT PISTON INTO CYLINDER

3. INSTALL PUSH ROD ASSEMBLY WITH SNAP RING

 CL−13
CLUTCH − CLUTCH MASTER CYLINDER

4. INSTALL RESERVOIR TANK

(a) Install reservoir tank and new grommet.
(b) Using a pin punch and a hammer, drive in the slotted spring
pin.

MASTER CYLINDER INSTALLATION

1. INSTALL MASTER CYLINDER
Install the mounting nut, and torque them.
Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf)
2. CONNECT CLUTCH LINE UNION
Using SST, connect the union.
SST 09023−00100
3. CONNECT PUSH ROD AND INSTALL PIN
Install the clip in the push rod pin.
4. BLEED SYSTEM AND ADJUST CLUTCH PEDAL
(See page CL−6, 7)
 CL−7
CLUTCH − CLUTCH PEDAL

CLUTCH PEDAL
CLUTCH PEDAL CHECK AND
ADJUSTMENT
1. CHECK THAT PEDAL HEIGHT AND PUSH ROD PLAY
ARE CORRECT
Pedal height from flower panel:
157.5 mm (6.201 in.)
Pedal height from asphalt sheet:
2WD 154.5 mm (6.0827 in.)
4WD 151.5 mm (5.9646 in.)
Push rod play at pedal top:
1.0−5.0 mm (0.039−0.197 in.)
If incorrect, adjust the pedal height and push rod play.
2. IF NECESSARY, ADJUST PEDAL HEIGHT AND PUSH
ROD PLAY
(a) Loosen the lock nut and turn the stopper bolt until the height
is correct. Tighten the lock nut.
(b) Loosen the lock nut and turn the push rod until the push rod
play is correct. Tighten the lock nut.
3. CHECK THAT PEDAL FREEPLAY IS CORRECT
Push in on the pedal until the beginning of clutch resistance
is felt.
Pedal freeplay:
5.0−15.0 mm (0.20−0.59 in.)
4. IF NECESSARY, ADJUST PEDAL FREEPLAY
(a) Loosen the lock nut and turn the push rod until the freeplay
is correct.
(b) Tighten the lock nut.
(c) After adjusting the pedal freeplay, check the pedal height.

5. CHECK CLUTCH RELEASE POINT

(a) Pull the parking brake lever and install wheel stopper.
(b) Start the engine and idle the engine.
(c) Without depressing the clutch pedal, slowly shift the shift
lever into reverse position until the gears contact.
(d) Gradually depress the clutch pedal and measure the stroke
distance from the point the gear noise stops (release point)
up to the full stroke end position.
CL−8
CLUTCH − CLUTCH PEDAL

Standard distance:
25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance not as specified, perform the following opera-
tion.
• Inspect pedal height.
• Inspect push rod play and pedal freeplay.
• Bleed the clutch line.
• Inspect the clutch cover and disc.

6. CHECK CLUTCH START SYSTEM

(a) Check that the engine does not start when the clutch pedal
is released.
(b) Check that the engine starts when the clutch pedal is fully
depressed.
(c) Check that clearance ”A” is greater than 1 mm (0.04 in.) when
the clutch is fully depressed.
If necessary, adjust or replace the clutch start switch.

7. CHECK CONTINUITY OF CLUTCH START SWITCH

(a) Check that there is continuity between terminals when the
switch is ON (pushed).
(b) Check that there is no continuity between terminals when the
switch is OFF (free).
If continuity is not as specified, replace the switch.

8. ADJUST CLUTCH START SWITCH

(a) Measure the pedal stroke, and check the switch clearance
”A” using the chart left.
(b) Loosen and adjust the switch position.
 CL−9
CLUTCH − CLUTCH PEDAL

(c) Recheck that the engine does not start when the clutch pedal
is released.

9. CHECK CONTINUITY OF CLUTCH START CANCEL

SWITCH
(a) Check that there is no continuity when connect the positive
(+) lead from the ohmmeter to terminal 2 and the negative (−)
lead to terminal 1.

(b) Check that there is no continuity when connect the positive

(+) lead from the ohmmeter to terminal 3 and the negative (−)
lead to terminal 1.
(c) Check that there is no continuity between terminals 2 and 3.
If continuity is not as specified, replace the clutch start cancel
switch.

10. CHECK OPERATION OF CLUTCH START CANCEL

SWITCH
(a) Connect positive (+) lead from the battery to terminal 3 and
connect negative (−) lead to terminal 1.
(b) Check that there is no continuity when connect the positive
(+) lead from the ohmmeter to terminal 2 and the negative (−)
lead to terminal 1.

(c) When pushing the switch, check that the indicator light
comes on and there is continuity between terminal 1 and 2.
CL−10
CLUTCH − CLUTCH PEDAL

(d) Check that there is no continuity between terminals 1 and 2

when disconnect the battery lead.
If operation is not as specified, replace the clutch start cancel
switch.
CL−14
CLUTCH − CLUTCH RELEASE CYLINDER

CLUTCH RELEASE CYLINDER

COMPONENTS

RELEASE CYLINDER REMOVAL

1. DISCONNECT CLUTCH LINE UNION
Using SST, disconnect the union.
SST 09023−00100
2. REMOVE 2 BOLTS AND PULL OFF RELEASE CYLINDER

RELEASE CYLINDER DISASSMBLY

1. PULL OUT PUSH ROD
2. REMOVE BOOT
3. REMOVE PISTON
 CL−15
CLUTCH − CLUTCH RELEASE CYLINDER

RELEASE CYLINDER INSPECTION

HINT: Clean the disassembled parts with compressed air.
1. INSPECT RELEASE CYLINDER BORE FOR SCORING OR
CORROSION
If a problem is found, clean or replace the cylinder.
2. INSPECT PISTON AND CUPS FOR WEAR, SCORING,
CRACKS OR SWELLING
If either one requires replacement, use the parts from the cyl-
inder kit.
3. INSPECT PUSH ROD FOR WEAR OR DAMAGE
If necessary, replace the push rod.

RELEASE CYLINDER ASSEMBLY

1. COAT PISTON WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
2. INSTALL PISTON
3. INSTALL BOOT AND INSERT PUSH ROD

RELEASE CYLINDER INSTALLATION

1. INSTALL RELEASE CYLINDER WITH 2 BOLTS
Torque: 12 N⋅m (120 kgf⋅cm, 9 ft⋅lbf)
2. CONNECT CLUTCH LINE TUBE
Using SST, connect the tube.
SST 09023−00100
3. BLEED CLUTCH SYSTEM
(See page CL−6)
CL−6
CLUTCH − CLUTCH SYSTEM BLEEDING

CLUTCH SYSTEM BLEEDING

HINT: If any work is done on the clutch system or if air is sus-
pected in the clutch lines, bleed the system of air.
NOTICE: Do not let brake fluid remain on a painted sur-
face. Wash it off immediately.
1. FILL CLUTCH RESERVOIR WITH BRAKE FLUID
2. CONNECT VINYL TUBE TO BLEEDER PLUG
Insert the other end of the tube in a half−full container of
brake fluid.
3. BLEED CLUTCH LINE
HINT: Check the reservoir frequently. Add fluid if necessary.
(a) Slowly pump the clutch pedal several times.
(b) While pressing on the pedal, loosen the bleeder plug until the
fluid starts to run out. Then close the bleeder plug.
SST 09023−00100
(c) Repeat this procedure until there are no more air bubbles in
the fluid.
CL−16
CLUTCH − CLUTCH UNIT

CLUTCH UNIT
COMPONENTS

CLUTCH UNIT REMOVAL

1. REMOVE TRANSMISSION FROM ENGINE
(See page G58 MT1−8, R150F MT3−9, 15, W55 MT2−9,
W56 MT2−15)
HINT: Do not drain the transmission oil.
 CL−17
CLUTCH − CLUTCH UNIT

2. REMOVE CLUTCH COVER AND DISC

(a) Place matchmarks on the clutch cover and flywheel.
(b) Loosen the set bolt one turn at a time until spring tension is
released.
(c) Remove the set bolts and pull off the clutch cover and disc.
NOTICE: Do not drop the clutch disc.

3. REMOVE BOOT, RELEASE BEARING AND FORK FROM

TRANSMISSION
(a) Remove the retaining clip pull off the bearing.
(b) Remove the fork and boot.

CLUTCH PARTS INSPECTION

1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using calipers, measure the rivet head depth.
Minimum rivet depth:
0.3 mm (0.012 in.)
If a problem is found, repair or replace the clutch disc.

2. INSPECT CLUTCH DISC RUNOUT

Using a dial indicator, check the disc runout.
Maximum runout:
0.8 mm (0.031 in.)
If runout is excessive, replace the disc.

3. INSPECT FLYWHEEL RUNOUT

Using a dial indicator, check the flywheel runout.
Maximum runout:
0.1 mm (0.004 in.)
If runout is excessive, repair or replace flywheel.
CL−18
CLUTCH − CLUTCH UNIT

4. INSPECT PILOT BEARING

Turn the bearing by hand while applying force in the rotation
direction.
It the bearing sticks or has much resistance, replace the pilot
bearing.
HINT: The bearing is permanently lubricated and requires no
cleaning or lubrication.

5. IF NECESSARY, REPLACE PILOT BEARING

(a) Using SST, remove the pilot bearing.
SST 09303−35011

(b) Using SST and hammer, install the pilot bearing.

SST 09304−30012
HINT: After assembling the pilot bearing to the hub, insure
that it rotates smoothly.

6. INSPECT DIAPHRAGM SPRING FOR WEAR

Using calipers, measure the diaphragm spring for depth and
width of wear.
Maximum:
A: Depth 0.6 mm (0.024 in.)
B: Width 5.0 mm (0.197 in.)

7. INSPECT RELEASE BEARING

Turn the bearing by hand while applying force in the rotation
direction.
If the bearing sticks or has much resistance, replace the re-
lease bearing.
HINT: The bearing is permanently lubricated and requires no
cleaning or lubrication.
 CL−19
CLUTCH − CLUTCH UNIT

CLUTCH UNIT INSTALLATION

1. INSTALL DISC ON FLYWHEEL
Using SST, install the disc on the flywheel.
SST 09301−20020

2. INSTALL CLUTCH COVER

(a) Align the matchmarks on the clutch cover and flywheel.
(b) Torque the bolts on the clutch cover in the order shown.
Torque: 19 N⋅m (195 kgf⋅cm, 14 ft⋅lbf)
HINT: Temporarily tighten the No.1 and No.2 bolts.

3. CHECK DIAPHRAGM SPRING TIP ALIGNMENT

Using a dial indicator with roller instrument, check the dia-
phragm spring tip alignment.
Maximum non−alignment.
0.5 mm (0.020 in.)
If alignment is not as specified, using SST, adjust the dia-
phragm spring tip alignment.
SST 09333−00013

4. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE

GREASE (NLGI NO.2) OR MP GREASE
(a) Apply molybdenum disulphide lithium base grease to the
following parts:
• Release fork and hub contact point
• Release fork and push rod contact point
• Release fork pivot point
• Clutch disc spline
(b) Apply MP grease to the front of the release bearing.

5. INSTALL BOOT, FORK, HUB AND BEARING ON

TRANSMISSION
6. INSTALL TRANSMISSION
(See page G58 MT1−11, R150F MT3−11, 18, W55 MT2−11,
W56 MT2−17)
 CL−1

CLUTCH
CL−2
CLUTCH − DESCRIPTION

DESCRIPTION
The diaphragm spring turnover type providing lighter release performance.
 CL−3
CLUTCH − DESCRIPTION
CL−4
CLUTCH − PREPARATION

PREPARATION
SST (SPECIAL SERVICE TOOLS)
09023−00100 Union Nut Wrench 10 mm Clutch line tube

09301−20020 Clutch Guide Tool

09303−35011 Input Shaft Front Bearing Puller

09304−30012 Input Shaft Front Bearing Replacer

09333−00013 Clutch Diaphragm Spring Aligner

RECOMMENDED TOOLS
09082−00050 TOYOTA Electrical Tester Set

09905−00013 Snap Ring Pliers

EQUIPMENT
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Calipers
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Dial indicator
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Torque wrench
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CL−20
CLUTCH − SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS
SERVICE DATA
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Pedal height from floor panel 157.5 mm (6.201 in.)

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Pedal height from asphalt sheet (2WD) 151.4 mm (6.08 in.)

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Pedal height from asphalt sheet (4WD) 151.5 mm (5.97 in.)

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Push rod play at pedal top
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1.0−5.0 mm (0.039−0.197 in.)

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Pedal freeplay 5.0−15.0 mm (0.197−0.591 in.)

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Clutch release point from pedal full stroke and position

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Disc rivet head depth (Minimum)
25 mm (0.98 in.) or more
0.3 mm (0.012 in.)

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Disc runout (Maximum) 0.8 mm (0.031 in.)

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Diaphragm spring tip non−alignment (Maximum)

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Diaphragm spring finger wear (Maximum depth)
0.5 mm (0.020 in.)
0.6 mm (0.024 in.)

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Diaphragm spring finger wear (Maximum width)

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5.0 mm (0.197 in.)

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Flywheel runout (Maximum) 0.1 mm (0.004 in.)

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TORQUE SPECIFICATIONS
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Part tightened

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N⋅m kgf⋅cm ft⋅lbf

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Clutch line union 15 155 11

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Bleeder plug
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Master cylinder installation nut

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13
11
130
110
9
8

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Clutch cover X Flywheel 19 195 14

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Release fork support
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Release cylinder installation bolt

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12
47
120
480
9
35

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22R−E 39 400 29
 TROUBLESHOOTING
cause of the problem. Check each part in order. If necessary, replace these parts.
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
Clutch slips

Clutch noisy

Clutch pedal spongy

Clutch does not disengage

Clutch grabs/chatters

Parts Name

See Page
Trouble
Clutch pedal (Freeplay out of adjustment) CL−7

Clutch line (Air in line) CL−6

Master cylinder cup (Damaged) CL−11

Release cylinder cup (Damaged) CL−14

CLUTCH
Engine mounting (Loosen)

Release bearing (Worn, dirty or damaged) CL−16

Input shaft bearing (Worn or damaged) CL−16

−
Clutch disc (Out of true) CL−16

TROUBLESHOOTING
Clutch disc (Runout is excessive) CL−16

Clutch disc (Lining broken) CL−16

Clutch disc (Dirty or burred) CL−16

Clutch disc (Oily) CL−16

Clutch disc (Worn out) CL−16

Clutch disc torsion rubber (Damaged) CL−16

Clutch disc (Harden) CL−16

Clutch disc (Lack o9f spline grease) CL−19

Diaphragm spring (Damaged) CL−16

Diaphragm spring (Out of tip alignment) CL−19

Pressure plate (Distortion) CL−16

Flywheel (Distortion)

CL−5