Toyota Pick-ups, Land Cruiser, and 4 Runner 1997-00

Driven Disc and Pressure Plate

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REMOVAL & INSTALLATION




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

  1. Remove the transmission.
  2.  



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Fig. View of the clutch and pressure plate assembly

  1. Matchmark the clutch cover (pressure plate) and flywheel, indicating their relationship.
  2.  



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Fig. Matchmark the pressure plate and flywheel



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Fig. Remove the clutch and pressure plate bolts

  1. Loosen the clutch cover-to-flywheel retaining bolts, one turn at a time, in a crisscross pattern. The pressure on the clutch disc must be released GRADUALLY.
  2.  



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Fig. Carefully pry the clutch and pressure plate assembly away from the flywheel

  1. Remove the clutch cover-to-flywheel bolts. Remove the clutch cover and the clutch disc.
  2.  



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Fig. Remove the clutch and pressure plate



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Fig. View of the flywheel once the clutch assembly is removed

  1. If the clutch throw-out 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.  

  2.  



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Fig. View of the clutch release fork; check it for signs of damage



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Fig. View of the clutch release fork bearing clips; make sure these are not bent or broken



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Fig. Removing the clutch release fork bearing clips



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Fig. Grease the throw-out bearing assembly at the outer contact points



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Fig. Grease the throw-out bearing assembly at the inner contact points



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Fig. Installing the clutch release fork bearing clip



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Fig. View of the clutch release fork assembly installed; be sure all parts move freely



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Fig. Exploded view of the common clutch set-up

  1. The bearing is press fit to the hub. Turn the bearing by hand while placing it under some pressure. Check for freedom of motion and lack of grinding or resistance. The bearing is permanently lubricated and cannot be disassembled or greased.
  2.  



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Fig. Lock the flywheel in place, and then remove the flywheel bolts



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Fig. Removing the flywheel from the crankshaft

  1. Clean all parts; lightly grease the input shaft splines and all of the contact points.
  2.  
  3. Install the bearing/hub assembly, fork, boot, and retaining clip(s) in their original locations.
  4.  



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Fig. Add a thread-locking agent to the flywheel bolts upon installation



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Fig. Be sure that the flywheel surface is clean before installing the clutch



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Fig. Place a straightedge across the flywheel surface, then use a feeler gauge to check for warpage



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Fig. Checking the pressure plate for excessive wear

  1. 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, replace the seal(s). If in doubt concerning the condition of the flywheel, consult an automotive machine shop.
  2.  



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Fig. Install a clutch alignment arbor to align the clutch assembly during installation



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Fig. Clutch plate installed with the arbor in place



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Fig. Clutch plate and pressure plate installed with the alignment arbor in place



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Fig. Pressure plate-to-flywheel bolt holes should align

  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. Grease or fingerprints may be cleaned with an evaporative cleaner such as the type used on brake linings.
  2.  



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Fig. Apply locking agent to the clutch assembly bolts



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Fig. Be sure to use a torque wrench to tighten all bolts in a star pattern



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Fig. Grease the clutch release fork ball

To install:

  1. Position the clutch disc against the flywheel. The long side of the splined section faces the flywheel.
  2.  
  3. Install the clutch cover over the disc and install the bolts loosely. Align the matchmarks made. If a new or rebuilt clutch cover assembly is installed, use the matchmark on the old cover assembly as a reference.
  4.  

Whenever the clutch disc is replaced, replacement of the pressure plate (clutch cover) and release bearing is highly recommended.

  1. Align the clutch disc with the flywheel using a clutch aligning tool. These handy tools are available in many auto parts stores at a reasonable price. Do NOT attempt to align the clutch disc by eye; use an alignment tool.
  2.  
  3. With the clutch aligning tool installed, tighten the clutch cover bolts gradually in a star pattern, as is done with lug nuts. Final tighten the bolts to 14 ft. lbs. (19 Nm).
  4.  
  5. Apply molybdenum disulfide grease, or multi-purpose grease, to the release fork contact points, the pivot and the clutch disc splines. Install the boot, fork, and bearing on the transmission input shaft.
  6.  
  7. Install the transmission.
  8.  

 
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