CLUTCH UNIT(for RC60, RC61) INSPECTION

PROCEDURE

1. INSPECT CLUTCH DISC ASSEMBLY

   
   

   1. 

      Using a vernier caliper, measure the rivet head depth.

      Minimum rivet head depth
      0.3 mm (0.0118 in.)

      If the depth is less than the minimum, replace the clutch disc assembly.

      Note

      
      

      • When replacing the Luk clutch disc, replace it together with the clutch cover.

      • 

        *a	Matching Number

        Make sure to use a Luk clutch disc and clutch cover with the same matching numbers as shown at the position indicated by the arrow in the illustration.

   2. 

      Using a dial indicator, check the disc runout.

      Maximum runout
      0.8 mm (0.0314 in.)

      Note

      Be sure to measure on the correct side of the clutch disc.

      If the runout is more than the maximum, replace the clutch disc assembly.

      Note

      
      

      • When replacing the Luk clutch disc, replace it together with the clutch cover.

      • 

        *a	Matching Number

        Make sure to use a Luk clutch disc and clutch cover with the same matching numbers as shown at the position indicated by the arrow in the illustration.

2. INSPECT CLUTCH COVER ASSEMBLY (for GD Series Engine)

   
   
   1. 

      *a	Width
      *b	Depth
      *A	except Luk made
      *B	for Luk made

      Using a vernier caliper, measure the depth and width of the worn areas of the diaphragm spring.

      Maximum width
      6.0 mm (0.236 in.)

      Maximum depth
      0.35 mm (0.0137 in.)

      If the depth or width is more than the maximum, replace the clutch cover assembly.

      Note

      
      

      • When replacing the Luk clutch disc, replace it together with the clutch cover.

      • 

        *a	Matching Number

        Make sure to use a Luk clutch disc and clutch cover with the same matching numbers as shown at the position indicated by the arrow in the illustration.

3. INSPECT FLYWHEEL SUB-ASSEMBLY

   
   

   1. 

      Using a dial indicator, measure the flywheel runout.

      Maximum runout
      0.1 mm (0.00393 in.)

      If the runout is more than the maximum, replace the flywheel sub-assembly.

4. INSPECT CLUTCH RELEASE BEARING ASSEMBLY

   
   

   1. 

      Turn the bearing by hand while applying force in the axial direction and check that the bearing rotates smoothly.

      If the bearing sticks or a considerable amount of resistance is felt, replace the release bearing.

      Tech Tips

      The bearing is permanently lubricated and requires no cleaning or lubrication.

5. INSPECT INPUT SHAFT FRONT BEARING

   
   

   1. 

      Turn the bearing by hand while applying rotational force and check that the bearing rotates smoothly.

      If the bearing sticks or a considerable amount of resistance is felt, replace the input shaft front bearing.

      Tech Tips

      The bearing is permanently lubricated and requires no cleaning or lubrication.

6. REPLACE INPUT SHAFT FRONT BEARING

   
   

   1. Remove any 2 diametrically opposite bolts.

   2. 

      Using SST, remove the input shaft front bearing.

      SST

      09303-35011

   3. 

      Using SST and a hammer, tap in a new input shaft front bearing.

      SST

      09304-12012

      Tech Tips

      After installing the bearing to the crankshaft, make sure that it rotates smoothly.

   4. Apply adhesive to 2 or 3 threads of the bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

   5. Install the 2 bolts.

      Torque:

      178 N*m  { 1815 kgf*cm, 131 ft.*lbf }