1996 TOYOTA TERCEL Service Repair Manual

CL05V-03
Z14165
Release Cylinder
Spring
Piston
Push Rod
Boot Clutch Line
- CLUTCHCLUTCH RELEASE CYLINDER
CL-9
704 Author
: Date
:
1996 TERCEL (RM440U)
CLUTCH RELEASE CYLINDER
COMPONENTS

CL05W-01
Q06706SST CL-10
- CLUTCHCLUTCH RELEASE CYLINDER
1996 TERCEL (RM440U)
REMOVAL
1. DISCONNECT CLUTCH LINE
Using SST, disconnect the line. Use a container to catch the
fluid.
SST 09023-00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
2. REMOVE 2 BOLTS AND PULL OUT RELEASE CYL-
INDER
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)

CL05X-01
Q06678
- CLUTCHCLUTCH RELEASE CYLINDER
CL-1 1
1996 TERCEL (RM440U)
DISASSEMBLY
1. PULL OUT BOOT WITH PUSH ROD
2. REMOVE PISTON
Using compressed air, remove the piston with the spring from
the cylinder.

CL05Y-01
CL0672
CL-12
- CLUTCHCLUTCH RELEASE CYLINDER
1996 TERCEL (RM440U)
REASSEMBLY
1. COAT PISTON WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
2. INSTALL PISTON WITH SPRING INTO CYLINDER
3. INSTALL BOOT WITH PUSH ROD TO CYLINDER

CL05Z-03
- CLUTCHCLUTCH RELEASE CYLINDER
CL-13
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page CL-10).
HINT:
After installation, bleed clutch system.

CL060-03
Z14164
Flywheel
Clutch Disc
Clutch Cover
Boot Release Fork Release Bearing with Hub X6 CL-14
- CLUTCHCLUTCH UNIT
709 Author
: Date
:
1996 TERCEL (RM440U)
CLUTCH UNIT
COMPONENTS

CL061-01
CL0288Matchmarks
N00413
- CLUTCHCLUTCH UNIT
CL-15
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE TRANSAXLE FROM ENGINE
(See page MX-4)
2. REMOVE CLUTCH COVER AND DISC
(a) Place matchmarks on the flywheel and clutch cover.
(b) Loosen each set bolt one turn at a time until spring tension
is released.
(c) Remove the set bolts, and pull off the clutch cover with the
clutch disc.
NOTICE:
Do not drop the clutch disc.
3. REMOVE RELEASE BEARING AND FORK FROM
TRANSAXLE
Remove the release bearing together with the fork and then
separate them.

CL062-01
CL0239
CL0373
CL0290
Z08001
AB
N00414
CL-16
- CLUTCHCLUTCH UNIT
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using calipers, measure the rivet head depth.
Minimum rivet depth: 0.3 mm (0.012 in.)
If necessary, replace the clutch disc.
2. INSPECT CLUTCH DISC RUNOUT
Using a dial indicator, check the disc runout.
Maximum runout: 0.8 mm (0.031 in.)
If necessary, replace the clutch disc.
3. INSPECT FLYWHEEL RUNOUT
Using a dial indicator, check the flywheel runout.
Maximum runout: 0.1 mm (0.004 in.)
If necessary, replace the flywheel.
4. INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth and
width of wear.
Maximum depth:
A: 0.6 mm (0.024 in.)
Maximum width:
B: 5.0 mm (0.197 in.)
If necessary, replace the clutch cover.
5. INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial direc-
tion.
HINT:
The bearing is permanently lubricated and requires no cleaning
or lubrication.
If necessary, replace the release bearing.