ES300 1992-1997

Driven Disc & Pressure Plate

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Adjustments



Specific to:

Lexus ES250 1990-1991

Lexus ES300 1992-1993

  1. Adjust the clearance between the master cylinder piston and the pushrod to specification by loosening the pushrod locknut and rotating the pushrod while depressing the clutch pedal lightly.
  2.  
  3. Tighten the locknut when finished with the adjustment.
  4.  
  5. Adjust the release cylinder free-play by loosening the release cylinder pushrod locknut and rotating the pushrod until proper specification is obtained.
  6.  
  7. Measure the clutch pedal free-play after performing the adjustments. If it fails to fall within specification, repeat the procedure.
  8.  

Removal & Installation



Specific to:

Lexus ES300 1992-1993

  1. Disconnect the negative battery cable. Wait at least 90 seconds before proceeding with any other work.
  2.  
  3. Remove the transaxle/transmission assembly from the vehicle.
  4.  
  5. Place matchmarks on the flywheel and clutch cover.
  6.  
  7. Remove the clutch pressure plate retaining bolts. Loosen the bolts 1 turn at a time, in a criss-cross pattern, until all the spring tension is released.
  8.  
  9. Remove the pressure plate and clutch disc. Do not drop the clutch disc or plate.
  10.  
  11. Remove the release bearing, fork and boot from the transmission.

    Click image to see an enlarged view

    Fig. Clutch disc and pressure plate assembly

  12.  

To install:

  1. Apply grease to the following;

    Release fork and hub contact points
     
    Release fork and pushrod contact point
     
    Release fork pivot point
     
    Clutch disc spline
     

  2.  
  3. Install a new release bearing on the fork and install the fork to the transaxle/transmission.
  4.  
  5. Install the clutch disc and pressure plate on the flywheel, aligning them with 09301-17010 or equivalent.
  6.  
  7. Tighten the pressure plate mounting bolts to 14 ft. lbs. (19 Nm) in X-type pattern.

    Click image to see an enlarged view

    Fig. Pressure plate bolt torque sequence

  8.  
  9. Install the transaxle/transmission.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Adjust the clutch pedal as necessary.
  14.  
  15. Road test the vehicle and verify proper clutch operation.
  16.  

 
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