Toyota RAV4 2000-05

Driven Disc & Pressure Plate

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Removal & Installation





Click image to see an enlarged view

Fig. Clutch component assembly-2001-03



Click image to see an enlarged view

Fig. Clutch components-2004

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Transaxle
     

  4.  
  5. Matchmark the clutch cover to the flywheel.
  6.  
  7. Remove the clutch pressure plate retaining bolts in small amounts and in a crisscross pattern to relieve the clutch disc spring tension.
  8.  
  9. At the clutch cover, loosen each bolt 1 turn until spring tension is released.
  10.  
  11. Remove or disconnect the following:

    Clutch cover set bolts and pull off the clutch cover with the clutch disc
     
    Clutch cover-to-flywheel bolts
     

  12.  
  13. If the clutch release bearing is to be replaced, perform the following:
    1. Remove the bearing retaining clip(s), the bearing and hub.
    2.  
    3. Remove the release fork and the boot.
    4.  
    5. The bearing is press fitted to the hub.
    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, the fork, the boot and the retaining clip(s) in their original locations.
    10.  

  14.  

To install:

  1. Inspect the flywheel surface for cracks, heat scO-ring (blue marks) and warpage. Replace or resurface the flywheel, if any damage is present.
  2.  


NOTE
Before installing any new parts, be sure they are clean. During installation, do not get grease or oil on any of the components, as this will shorten clutch life considerably.

  1. Using a clutch alignment tool, position the clutch disc against the flywheel. The raised center section of the disc faces the transaxle.
  2.  
  3. Install or connect the following:

    Clutch cover onto the flywheel by aligning the matchmarks
     
    Clutch cover. Tighten the bolts in a crisscross pattern to 14 ft. lbs. (19 Nm).
     

  4.  
  5. Lubricate the release fork pivot and contact points, release bearing, bearing hub and input shaft spline surfaces with a suitable molybdenum disulfide lithium based or multi-purpose grease.
  6.  
  7. Install or connect the following:

    Boot, release fork, hub and the bearing assemblies
     
    Transaxle
     
    Negative battery cable
     

  8.  


    Click image to see an enlarged view

    Fig. Torque sequence for the clutch cover




Click image to see an enlarged view

Fig. Clutch component assembly-Exploded view

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Transaxle
     

  4.  
  5. Matchmark the clutch cover to the flywheel.
  6.  
  7. Remove the clutch pressure plate retaining bolts in small amounts and in a crisscross pattern to relieve the clutch disc spring tension.
  8.  
  9. At the clutch cover, loosen each bolt 1 turn until spring tension is released.
  10.  
  11. Remove or disconnect the following:

    Clutch cover set bolts and pull off the clutch cover with the clutch disc
     
    Clutch cover-to-flywheel bolts
     

  12.  
  13. If the clutch release bearing is to be replaced, perform the following:
    1. Remove the bearing retaining clip(s), the bearing and hub.
    2.  
    3. Remove the release fork and the boot.
    4.  
    5. The bearing is press fitted to the hub.
    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, the fork, the boot and the retaining clip(s) in their original locations.
    10.  

  14.  

To install:

  1. Inspect the flywheel surface for cracks, heat scoring (blue marks) and warpage. Replace or resurface the flywheel, if any damage is present.
    NOTE
    Before installing any new parts, be sure 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. Using a clutch alignment tool, position the clutch disc against the flywheel. The raised center section of the disc faces the transaxle.
  4.  
  5. Install or connect the following:

    Clutch cover onto the flywheel by aligning the matchmarks
     
    Clutch cover. Tighten the bolts in a crisscross pattern to 14 ft. lbs. (19 Nm).

    Click image to see an enlarged view

    Fig. Torque sequence for the clutch cover-RAV4

     

  6.  
  7. Lubricate the release fork pivot and contact points, release bearing, bearing hub and input shaft spline surfaces with a suitable molybdenum disulfide lithium based or multi-purpose grease.
  8.  
  9. Install or connect the following:

    Boot, release fork, hub and the bearing assemblies
     
    Transaxle
     
    Negative battery cable
     

  10.  



Click image to see an enlarged view

Fig. Clutch and related components-2000-2003



Click image to see an enlarged view

Fig. Clutch and related components-2004-2005

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Transaxle
     

  4.  
  5. Matchmark the clutch cover to the flywheel.
  6.  
  7. Remove the clutch pressure plate retaining bolts in small amounts and in a crisscross pattern to relieve the clutch disc spring tension.
  8.  
  9. At the clutch cover, loosen each bolt 1 turn until spring tension is released.
  10.  
  11. Remove or disconnect the following:

    Clutch cover set bolts and pull off the clutch cover with the clutch disc
     
    Clutch cover-to-flywheel bolts
     

  12.  
  13. If the clutch release bearing is to be replaced, perform the following:
    1. Remove the bearing retaining clip(s), the bearing and hub.
    2.  
    3. Remove the release fork and the boot.
    4.  
    5. The bearing is press fitted to the hub.
    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, the fork, the boot and the retaining clip(s) in their original locations.
    10.  

  14.  

To install:

  1. Inspect the flywheel surface for cracks, heat scoring (blue marks) and warpage. Replace or resurface the flywheel, if any damage is present.
    NOTE
    Before installing any new parts, be sure 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. Using a clutch alignment tool, position the clutch disc against the flywheel. The raised center section of the disc faces the transaxle.
  4.  
  5. Install or connect the following:

    Clutch cover onto the flywheel by aligning the matchmarks
     
    Clutch cover. Tighten the bolts in a crisscross pattern to 14 ft. lbs. (19 Nm).

    Click image to see an enlarged view

    Fig. Clutch bolt torque sequence

     

  6.  
  7. Lubricate the release fork pivot and contact points, release bearing, bearing hub and input shaft spline surfaces with a suitable molybdenum disulfide lithium based or multi-purpose grease.
  8.  
  9. Install or connect the following:

    Boot, release fork, hub and the bearing assemblies
     
    Transaxle
     
    Negative battery cable
     

  10.  

 
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