Page 11 of 1807
Q04326
Matchmarks
Secondary
FlywheelPrimary
Flywheel
Q04327
Matchmarks CL-24
- CLUTCHCLUTCH UNIT (2JZ-GTE)
1565 Author: Date:
1997 SUPRA (RM502U)
8. INSPECT FLYWHEEL DAMPER FOR GREASE LEAK-
AGE
If grease has sprayed onto the clutch housing, replace the fly-
wheel assembly.
9. INSPECT FLYWHEEL DAMPER ROTATIONAL FREE-
PLAY
(a) Install the 2 bolts to the secondary flywheel at diametrical-
ly opposite positions.
(b) Holding both the bolts, and turn the secondary flywheel
clockwise until it stops.
(c) Put matchmarks on the primary and secondary flywheels
at this position.
(d) Then rotate the primary flywheel counterclockwise by
hand until it stops.
(e) Put matchmarks on the primary flywheel at this position.
(f) Measure the circumferential length between the 2 match-
marks on the secondary flywheel.
Standard: 105 mm (4.134 in.)
(g) Repeat the previous steps (d) to (f) 4 times and if the mea-
surement is greater than the maximum length replace the
flywheel assembly (See page EM-88).
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 17 of 1807
CL040-01
Z16903
Filler Cap
Reservoir Tank
Slotted Spring
Pin
Clutch Line
Push Rod Grommet Float
Clip Pin
Clevis
Boot
Washer
Snap Ring
Lock Nut15 (155, 11)
12 (125, 9)
12 (125, 9)
N´m (kgf´cm, ft´lbf)
: Specified torque
Non-reusable partPiston
Master Cylinder Body
- CLUTCHCLUTCH MASTER CYLINDER
CL-5
1546 Author: Date:
1997 SUPRA (RM502U)
CLUTCH MASTER CYLINDER
COMPONENTS
Page 21 of 1807
MT06M-02
- MANUAL TRANSMISSION (V160)TROUBLESHOOTING
MT-1
1569 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
Noise
1. Flywheel damper
2. Oil (Level low)
3. Oil (Wrong)
4. Gear (Worn or damaged)
5. Bearing (Worn or damaged)CL-17
CL-22
MT-3
MT-3
-
-
Oil leakage
1. Oil (Level too high)
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O-Ring (Worn or damaged)MT-3
-
MT-7
MT-2
MT-7
Hard to shift or will not shift1. Synchronizer ring (Worn or damaged)
2. Shift key spring (Damaged)-
-
Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)-
-
-
-
Page 26 of 1807
MT06Q-01
Q08612
Companion Flange
10 (100, 7)
Oil Seal
Vehicle Speed SensorAdjusting Washer
Transmission Lock Plate
Lock Nut
11 (110, 8)
O-Ring
Release Fork Support
Release Fork Support Spring Front Bearing Retainer
26 (260, 19)
Oil Seal
Non-reusable part
N´m (kgf´cm, ft´lbf)
Precoated part: Specified torque
120 (1,220, 88)
- MANUAL TRANSMISSION (V160)OIL SEAL
MT-7
1575 Author: Date:
1997 SUPRA (RM502U)
OIL SEAL
COMPONENTS
Page 27 of 1807
MT06R-02
Q04145
Q04146
SST
Q04147
SST
Q04148
SST
Q04149
SST MT-8
- MANUAL TRANSMISSION (V160)OIL SEAL
1576 Author: Date:
1997 SUPRA (RM502U)
REPLACEMENT
1. REPLACE TRANSMISSION REAR OIL SEAL
(a) Remove the propeller shaft.
(See page PR-2)
(b) Using a screwdriver, remove the lock plate.
(c) Using SST to hold the flange, remove the lock nut.
SST 09330-00021
(d) Remove the 2 adjusting washers.
(e) Using SST, remove the companion flange.
SST 09950- 30010 (09951- 03010, 09953- 03010,
09954-03010, 09955-03030, 09956-03030)
(f) Using SST, remove the oil seal.
SST 09308-10010
(g) Using SST and a hammer, install a new oil seal.
SST 09308-14010, 09309-14040
Page 28 of 1807
Q04147
SST
Q04150
SST
Q04151
ºAº
ºBº
Q04150
SST
- MANUAL TRANSMISSION (V160)OIL SEAL
MT-9
1577 Author: Date:
1997 SUPRA (RM502U)
(h) Heat the companion flange in an oven.
Companion flange temperature:
80 - 90°C (176 - 194°F)
(i) Apply gear oil to the output shaft and install the compan-
ion flange.
(j) Using SST, install the companion flange to the output
shaft.
SST 09950- 30010 (09951- 03010, 09953- 03010,
09954-03010, 09955-03030, 09956-03030)
(k) Using SST to hold the flange, temporary install and torque
the lock nut.
SST 09330-00021
Torque: 190 N´m (1,940 kgf´cm, 140 ft´lbf)
(l) Remove the lock nut.
(m) Using a caliper gauge, measure dimension ºAº and di-
mension ºBº.
(n) Calculate the required thickness of the adjusting shim.
Thickness:
(Dimension ºAº - Dimension ºBº) - (0.05 ~ 0.14 mm,
0.0020 ~ 0.0055 in.)
Adjusting shim thickness mm (in.)Adjusting shim thickness mm (in.)
1.15 - 1.20 (0.0453 - 0.0472)1.65 - 1.70 (0.0650 - 0.0669)
1.25 - 1.30 (0.0492 - 0.0512)1.85 - 1.90 (0.0729 - 0.0748)
1.45 - 1.50 (0.0571 - 0.0591)1.95 - 2.00 (0.0768 - 0.0787)
(o) Install the selected shims to the output shaft.
(p) Apply sealant to the nut threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(q) Using SST to hold the flange, reinstall and torque the lock
nut.
SST 09330-00021
Torque: 120 N´m (1,220 kgf´cm, 88 ft´lbf)
Page 29 of 1807
Q04451
SST
Q04152
Q04153
Q04154SST
Q03816
MT-10
- MANUAL TRANSMISSION (V160)OIL SEAL
1578 Author: Date:
1997 SUPRA (RM502U)
(r) Using SST and a hammer, install a new lock plate.
SST 09309-14010
HINT:
If necessary, using a pin punch and hammer, and tap the lock
plate.
(s) Install the propeller shaft.
(See page PR-2)
2. REPLACE TRANSMISSION FRONT OIL SEAL
(a) Remove the transmission.
(See page MT-2)
(b) Remove the 2 bolts and release fork support.
(c) Remove the 4 bolts and front bearing retainer.
(d) Using a hammer, tap in the screwdriver to the oil seal.
(e) Pry out the oil seal.
(f) Using SST and a hammer, install a new oil seal.
SST 09308-14010, 09309-14040
(g) Install the transmission.
(See page MT-2)
(h) Install the front bearing retainer with the 4 bolts.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
(i) Install the release fork support with the 2 bolts.
Torque: 26 N´m (260 kgf´cm, 19 ft´lbf)
3. REPLACE VEHICLE SPEED SENSOR O-RING
(a) Remove the transmission.
(See page MT-2)
(b) Remove the set bolt and driven gear.
(c) Remove the O-ring from the driven gear.
(d) Install a new O-ring to the driven gear.
(e) Apply sealant to the bolt threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
