Page 1 of 1807
CL03Y-02
- CLUTCHTROUBLESHOOTING
CL-1
1542 Author: Date:
1997 SUPRA (RM502U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Clutch grabs/chatters
1. Engine mounting (Loosen)
2. Clutch disc (Runout is excessive)
3. Clutch disc (Oily)
4. Clutch disc (Worn out)
5. Clutch disc (Damaged torsion rubber)
6. Clutch disc (Glazed)
7. Diaphragm spring (Out of tip alignment)-
CL-15
CL-20
CL-15
CL-20
CL-15
CL-20
CL-15
CL-20
CL-15
CL-20
CL-19
CL-25
Clutch pedal spongy
1. Clutch line (Air in line)
2. Master cylinder cup (Damaged)
3. Release cylinder cup (Damaged)-
CL-5
CL-10
Clutch noisy
1. Release bearing (Worn, dirty or damaged)
2. Pilot bearing (Worn or damaged)
3. Input shaft bearing (Worn, dirty or damaged)
4. Clutch disc torsion rubber (Damaged)CL-15
CL-20
CL-15
CL-20
-
CL-15
CL-20
Page 8 of 1807
CL04B-02
Q04195
Q04196
Q04197
Q04198
- CLUTCHCLUTCH UNIT (2JZ-GTE)
CL-21
1562 Author: Date:
1997 SUPRA (RM502U)
REMOVAL
1. REMOVE TRANSMISSION FROM ENGINE
(See page MT-2)
HINT:
Do not drain the transmission oil.
2. REMOVE RELEASE FORK ASSEMBLY
(a) Remove the release fork assembly from the left side of
clutch housing service hole.
(b) Remove the E-ring from the release fork.
(c) Remove the pin and wave washer from the release fork.
3. REMOVE CLUTCH DISC
4. REMOVE CLUTCH COVER ASSEMBLY
5. REMOVE CLUTCH RELEASE BEARING HUB
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the release bearing hub, thrust cone spring and
plate washer.
6. REMOVE CLUTCH RELEASE BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the release bearing, wave washer and plate
washer.
Page 14 of 1807
Q04216
Front
Q04195
- CLUTCHCLUTCH UNIT (2JZ-GTE)
CL-27
1568 Author: Date:
1997 SUPRA (RM502U)
8. INSTALL CLUTCH COVER ASSEMBLY
9. INSTALL CLUTCH DISC
NOTICE:
Install the clutch disc in the correct direction.
10. INSTALL RELEASE FORK ASSEMBLY
Install the release bearing assembly to the release fork assem-
bly, and install them to the transmission.
11. INSTALL TRANSMISSION TO ENGINE
(See page MT-2)
Page 15 of 1807
Q04160
Push Rod Play and
Freeplay Adjust Point
Pedal
HeightPedal Height
Adjust Point
Push Rod PlayCL03Z-01
CL0102Pedal Freeplay
Z13785
25 mm (0.98 in.) or more
Full Pedal Stroke Full Stroke
End PositionRelease
Point
- CLUTCHCLUTCH PEDAL
CL-3
1544 Author: Date:
1997 SUPRA (RM502U)
CLUTCH PEDAL
INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
146.2 - 156.2 mm (5.76 - 6.15 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
Loosen the lock nut and clutch switch until the height is correct.
Tighten the lock nut.
HINT:
Before rotating the clutch switch for pedal height adjustment,
disconnect the clutch switch connector.
3. CHECK PEDAL FREEPLAY AND PUSH ROD PLAY
Push in on the pedal until the beginning of clutch resistance is
felt.
Pedal freeplay: 5.0 - 15.0 mm (0.197 - 0.591 in.)
Gently push on the pedal until the resistance begins to increase
a little.
Push rod play at pedal top:
1.0 - 5.0 mm (0.039 - 0.197 in.)
4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND
PUSH ROD PLAY
(a) Loosen the lock nut and turn the push rod until the free-
play and push rod play are correct.
(b) Tighten the lock nut.
(c) After adjusting the pedal freeplay, check the pedal height.
5. INSPECT FULL PEDAL STROKE
Full pedal stroke: 132.0 - 138.0 mm (5.20 - 5.43 in.)
6. INSPECT CLUTCH RELEASE POINT
(a) Pull the parking brake lever and install wheel stopper.
(b) Start the engine and idle the engine.
(c) Without depressing the clutch pedal, slowly shift the shift
lever into the reverse position until the gears contact.
(d) Gradually depress the clutch pedal and measure the
stroke distance from the point the gear noise stops (re-
lease point) up to the full stroke end position.
Page 16 of 1807
Q04185
Clutch Start Switch
Q00617
8 ± 0.5 mm
(0.31 ± 0.020 in.) CL-4
- CLUTCHCLUTCH PEDAL
1545 Author: Date:
1997 SUPRA (RM502U)
Standard distance: 25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance is not as specified, do the following operation.
Inspect pedal height.
Inspect push rod play and pedal freeplay.
Bleed the clutch line.
Inspect the clutch cover and disc.
7. CHECK CLUTCH START SYSTEM
(a) Check that the engine does not start when the clutch ped-
al is released.
(b) Check that the engine starts when the clutch pedal is fully
depressed.
If necessary, adjust or replace the clutch start switch.
8. INSPECT CONTINUITY OF CLUTCH START SWITCH
(a) Check that there is continuity between the terminals when
the switch is ON (pushed).
(b) Check that there is no continuity between the terminals
when the switch is OFF (free).
If continuity is not as specified, replace the switch.
Page 22 of 1807
MT06N-01
D01920
Shift Lever Knob
Upper Console Panel
Shift Lever Boot
RetainerShift Lever Retainer
Shift and Select Lever
Boot No.1
x5
Service Hole
Cover
Starter
Pipe Support Bracket
Service Hole Cover
Ground Cable
Engine Under Cover
Oxygen SensorExhaust Front Pipe Exhaust Tail Pipe Exhaust Center PipePropeller ShaftCrossmember Brace
Heat Insulator Engine Rear
Mounting
Adjusting Washer BushingTransmission Shift Lever
Clutch Release Cylinder
N´m (kgf´cm, ft´lbf)Shift and Select Lever
Boot No.2
Oxygen Sensor Cover
: Specified torqueRear Engine Mounting
Member
Non-reusable part Gasket
Gasket
Gasket
Gasket
19 (195, 14)
72 (730, 53)
12 (120, 9)
79 (805, 58)
49 (500, 36)
19 (195, 14)
56 (570, 41)
12 (120, 9)
37 (380, 27)
12 (120, 9)
25 (260, 19)13 (135, 10)
39 (400, 29)
5.5 (55, 48 in.´lbf)
13 (130, 9)
13 (130, 9)
5.5 (55, 48 in.´lbf)
Heat Insulator72 (730, 53)
39 (400, 29)
25 (250, 18)19 (195, 14)
19 (195, 14)
7.8 (80, 69 in.´lbf)
Bushing
19 (195, 14)
Normal Roof:
Sport Roof:
58 (590, 43)
Transmission
Crossmember
Brace
20 (200, 14)
25 (250, 18)
58 (590, 43)
MT-2
- MANUAL TRANSMISSION (V160)MANUAL TRANSMISSION UNIT
1570 Author: Date:
1997 SUPRA (RM502U)
MANUAL TRANSMISSION UNIT
COMPONENTS
Page 23 of 1807
MT06O-01
Q04417
Q06365
Q09475
Filler Plug
Drain PlugOil Level
0 - 5 mm
Q04419
R06858
- MANUAL TRANSMISSION (V160)MANUAL TRANSMISSION UNIT
MT-3
1571 Author: Date:
1997 SUPRA (RM502U)
REMOVAL
1. REMOVE UPPER CONSOLE PANEL, SHIFT LEVER
BOOT RETAINER AND SHIFT AND SELECT LEVER
BOOTS NO.1 AND NO.2
(a) Remove the shift lever knob.
(b) Using a screwdriver, pry out the upper console panel.
(c) Remove the 4 bolts and boot retainer.
(d) Remove the shift and select lever boots No.1 and No.2.
2. REMOVE 4 TRANSMISSION SHIFT LEVER SET
BOLTS
Torque: 7.8 N´m (80 kgf´cm, 69 in.´lbf)
3. RAISE VEHICLE
NOTICE:
Make sure that the vehicle is securely supported.
4. DRAIN TRANSMISSION OIL
Oil type: TOYOTA GEAR OIL V160 or ESSO ATF
DEXRON®D-21065
Capacity: 1.8 liters (1.9 US qts, 1.6 Imp. qts)
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
5. REMOVE ENGINE UNDER COVER
6. REMOVE EXHAUST FRONT PIPE AND PIPE SUP-
PORT BRACKET
(a) Remove the 2 nuts, cover, oxygen sensor and gasket.
Torque: 20 N´m (200 kgf´cm, 14 ft´lbf)
(b) Remove the 2 bolts, nuts and gasket.
Torque: 58 N´m (590 kgf´cm, 43 ft´lbf)
(c) Remove the 2 bolts and pipe support bracket from the
clutch housing.
Torque: 37 N´m (380 kgf´cm, 27 ft´lbf)
(d) Remove the 2 bolts, nuts and gasket.
Torque: 58 N´m (590 kgf´cm, 43 ft´lbf)
(e) Remove the exhaust front pipe.
Page 25 of 1807
Q04136Matchmarks
Q04137
Q04138
Q04341
Q04141
A
B
A
- MANUAL TRANSMISSION (V160)MANUAL TRANSMISSION UNIT
MT-5
1573 Author: Date:
1997 SUPRA (RM502U)
15. REMOVE CLUTCH COVER SET BOLT
(a) Remove the 2 bolts and service hole cover.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
(b) Place matchmarks on the flywheel and clutch cover.
(c) Remove the 6 bolts.
Torque: 19 N´m (195 kgf´cm, 14 ft´lbf)
16. JACK UP TRANSMISSION SLIGHTLY
Using a transmission jack, support the transmission.
17. REMOVE REAR ENGINE MOUNTING MEMBER
Remove the 4 nuts, bolts and rear engine mounting member.
Torque:
Nut: 13 N´m (135 kgf´cm, 10 ft´lbf)
Bolt: 25 N´m (260 kgf´cm, 19 ft´lbf)
18. REMOVE STARTER
Lower the engine rear side and remove the 2 bolts and starter.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
19. REMOVE TRANSMISSION
Remove the 5 transmission mounting bolts and transmission
from the engine.
Torque: 72 N´m (730 kgf´cm, 53 ft´lbf)
20. REMOVE SHIFT LEVER RETAINER
Remove the 5 bolts, nut and shift lever retainer from the trans-
mission.
Torque:
Bolt A: 19 N´m (195 kgf´cm, 14 ft´lbf)
Nut B: 25 N´m (250 kgf´cm, 18 ft´lbf)
21. REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting from the trans-
mission.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
