Toyota Pick-ups/Land Cruiser/4Runner 1970-1988

Driven Disc and Pressure Plate

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REMOVAL & INSTALLATION



See Figures 1 through 31


CAUTION
The clutch driven disc contains asbestos, which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air! Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid.

  1. Remove the transmission.
  2.  
  3. Stamp or chalk matchmarks on the clutch cover and flywheel, indicating their relationship.
  4.  
  5. Loosen the clutch cover-to-flywheel retaining bolts one turn at a time. The pressure on the clutch disc must be released GRADUALLY.
  6.  
  7. Remove the clutch cover-to-flywheel bolts. Remove the clutch cover and the clutch disc.
  8.  
  9. If the clutch release bearing is to be replaced, do so at this time as follows:
    1. Remove the bearing retaining clip(s) and remove the bearing and hub.
    2.  
    3. Remove the release fork and the boot.
    4.  
    5. The bearing is press fitted to the hub. In some cases, the bearing is available with the hub from automotive suppliers. If this is not the case with your model, contact a machine shop and have the bearing replaced using a hydraulic press. Using other means to replace the bearing could result in personal injury.
    6.  
    7. Clean all parts and lightly grease the input shaft splines and all of the contact points.
    8.  
    9. Install the bearing/hub assembly, fork, boot, and retaining clip(s) in their original locations.
    10.  

  10.  
  11. Inspect the flywheel surface for cracks, heat scoring (blue marks), and warpage. If oil is present on the flywheel surface, this indicates that either the engine rear oil seal or the transmission front oil seal is leaking. If necessary, refer to the appropriate section for seal replacement. If in doubt concerning the condition of the flywheel, consult an automotive machine shop.
  12.  

To install:
  1. Before installing any new parts, make sure that they are clean. During installation, do not get grease or oil on any of the components, as this will shorten clutch life considerably.
  2.  
  3. Position the clutch disc against the flywheel. On Pick-Ups, the short side of the splined section faces the flywheel. On Land Cruisers, the long side of the splined section faces the flywheel.
  4.  
  5. Install the clutch cover over the disc and install the bolts loosely. Align the matchmarks made during Step 2. If a new or rebuilt clutch cover assembly is installed, use the matchmark on the old cover assembly as a reference.
  6.  
  7. Align the clutch disc with the flywheel using a clutch aligning tool, which is available in most auto stores at a reasonable price.
  8.  
  9. With the clutch aligning tool installed, tighten the clutch cover bolts gradually in a star pattern, as is done with lug nuts. Finally tighten the bolts to 14 ft. lbs. (19 Nm).
  10.  
  11. Install the transmission.
  12.  



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Fig. Fig. 1: Inspect the clutch disc for wear



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Fig. Fig. 2: Exploded view of the clutch assembly



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Fig. Fig. 3: Tightening the clutch disc-to-flywheel bolts



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Fig. Fig. 4: View of the clutch and pressure plate assembly



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Fig. Fig. 5: Removing the clutch and pressure plate bolts



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Fig. Fig. 6: Removing the clutch and pressure plate assembly



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Fig. Fig. 7: Removing the clutch and pressure plate



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Fig. Fig. 8: View of the flywheel



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Fig. Fig. 9: View of the flywheel bolts



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Fig. Fig. 10: Removing the flywheel bolts--lock the flywheel



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Fig. Fig. 11: Removing the flywheel



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Fig. Fig. 12: Check the flywheel bolts--add locking agent to bolts upon installation



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Fig. Fig. 13: Cleaning the flywheel--after installation



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Fig. Fig. 14: Checking the flywheel for wear



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Fig. Fig. 15: Checking the pressure plate for wear



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Fig. Fig. 16: Install special tool to align the clutch assembly



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Fig. Fig. 17: Clutch plate installed with tool



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Fig. Fig. 18: Clutch plate and pressure plate installed with special tool



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Fig. Fig. 19: Clutch assembly bolt holes



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Fig. Fig. 20: Install locking agent to clutch assembly bolts



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Fig. Fig. 21: Install the clutch assembly bolts and tighten in steps



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Fig. Fig. 22: Install the clutch assembly bolts and tighten in steps with torque wrench



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Fig. Fig. 23: Install grease on the clutch release fork ball



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Fig. Fig. 24: View of the clutch release fork



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Fig. Fig. 25: View of the clutch release fork bearing clips



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Fig. Fig. 26: Removing the clutch release fork bearing clips



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Fig. Fig. 27: Grease the throwout bearing assembly



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Fig. Fig. 28: Grease the throwout bearing assembly



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Fig. Fig. 29: Installing the clutch release fork bearing clip



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Fig. Fig. 30: View of the clutch release fork assembly--installed



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Fig. Fig. 31: View of special tool, used to install the clutch and pressure plate assembly

 
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