TRANSMISSION/TRANSAXLE

SECTION CL CLUTCH
B

CL

CONTENTS
SERVICE INFORMATION ............................ 2
PRECAUTIONS ................................................... 2
Service Notice or Precaution ..................................... 2
PREPARATION ................................................... 3
Special Service Tool ................................................. 3
Commercial Service Tool .......................................... 3
CLUTCH PEDAL ................................................. 5
On-Vehicle Inspection and Adjustment ..................... 5
Removal and Installation ........................................... 5
CLUTCH FLUID ................................................... 7
Air Bleeding Procedure ............................................. 7
CLUTCH MASTER CYLINDER ........................... 8
Component ................................................................ 8
Removal and Installation ........................................... 8
Disassembly and Assembly ...................................... 9
E
OPERATING CYLINDER .................................. 10 F
Component ..............................................................10
Removal and Installation .........................................10
G
CLUTCH PIPING ............................................... 11
Removal and Installation .........................................11
CLUTCH RELEASE MECHANISM ................... 13 H
Removal and Installation .........................................13
CLUTCH DISC, CLUTCH COVER AND FLY-
I
WHEEL .............................................................. 16
Removal and Installation .........................................16
SERVICE DATA AND SPECIFICATIONS J
(SDS) ................................................................. 18
Clutch Control System .............................................18
Clutch Master Cylinder ............................................18 K
Clutch Operating Cylinder .......................................18
Clutch Disc ..............................................................18
Clutch Cover ............................................................18
L

Revision: 2007 September CL-1 D40

 PRECAUTIONS
< SERVICE INFORMATION >
SERVICE INFORMATION
PRECAUTIONS
Service Notice or Precaution INFOID:0000000002978305

• Recommended clutch fluid is brake fluid “DOT 3”. Refer to MA-12, "Fluids and Lubricants".
• Do not reuse drained clutch fluid.
• Be careful not to splash clutch fluid on painted areas.
• Use a flare nut torque wrench [Commercial service tool], when
removing and installing clutch piping.
• Use new clutch fluid to clean or wash all parts of master cylinder
and operating cylinder.
• Do not use mineral oils such as gasoline or kerosene. It will cor-
rode the rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not
use compressed air.

PCIB0272E

Revision: 2007 September CL-2 D40

 PREPARATION
< SERVICE INFORMATION >
PREPARATION
A
Special Service Tool INFOID:0000000002978306

B
Tool number
Description
Tool name
KV30101400 Installing release bearing
CL
Drift
a: 51 mm (2.01 in) dia.
b: 44 mm (1.73 in) dia.
D

ZZA0838D
E
ST20050240 Adjusting unevenness of diaphragm spring of
Diaphragm adjusting wrench clutch cover

G
ZZA0508D

Commercial Service Tool INFOID:0000000002978307

H

Tool name Description

Pin punch Removing and installing master cylinder
I
Tip diameter: 4.5 mm (0.177 in) dia. spring pin

K
ZZA0515D

Clutch aligner Installing clutch disc

1: Center shaft
2: Attachment L
3: Guide

PCIB0017E

Flare nut torque wrench Removing and installing clutch piping N

a: 10 mm (0.39 in)

S-NT406
P

Revision: 2007 September CL-3 D40

 PREPARATION
< SERVICE INFORMATION >
Tool name Description
Flare nut torque wrench Removing and installing clutch piping (For YD
a: 14 mm (0.55 in) engine of LHD models)

S-NT406

Puller Removing release bearing

NT077

Revision: 2007 September CL-4 D40

 CLUTCH PEDAL
< SERVICE INFORMATION >
CLUTCH PEDAL
A
On-Vehicle Inspection and Adjustment INFOID:0000000002978308

1. Make sure that clevis pin floats freely in the bore of clutch pedal. B
It should not be bound by clevis or clutch pedal.
a. If clevis pin is not free, make sure that pedal stopper bolt (with-
out ASCD) or ASCD clutch switch (with ASCD) is not applying CL
pressure to clutch pedal causing clevis pin to bind. To adjust,
loosen lock nut and turn pedal stopper bolt (without ASCD) or
ASCD clutch switch (with ASCD).
D
b. Tighten lock nut.
c. Make sure that clevis pin floats in the bore of clutch pedal. It
should not be bound by clutch pedal.
PCIB0907E E
d. If clevis pin is still not free, remove clevis pin and check for
deformation or damage. Replace clevis pin if necessary. Leave the pin removed for step 2.
2. Check clutch pedal stroke for free range of movement.
F
a. With clevis pin removed, manually move clutch pedal up and down to determine if it moves freely.
b. If any sticking is found, replace related parts (clutch pedal, assist spring, bushing etc.). Re-assemble
clutch pedal and again make sure that clevis pin floats freely in the bore of clutch pedal.
G
3. Check clutch hydraulic and system components (clutch master cylinder, clutch operating cylinder, clutch
withdrawal lever, clutch release bearing, etc.) for sticking or binding.
a. If any sticking or binding is found, repair or replace related parts as necessary. H
b. If hydraulic system repair was necessary, bleed the clutch hydraulic system. Refer to CL-7, "Air Bleeding
Procedure".
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or I
power bleeder will not purge all the air from the system.
Removal and Installation INFOID:0000000002978309
J

COMPONENTS
LHD models K

P
PCIB2041E

1. Clutch pedal assembly 2. Clevis pin 3. Bushing

4. Stopper rubber 5. Pedal stopper bolt (Without ASCD) 6. ASCD clutch switch (With ASCD)
7. Pedal pad 8. Stopper rubber 9. Snap pin
10. Bushing 11. Assist spring

Revision: 2007 September CL-5 D40

 CLUTCH PEDAL
< SERVICE INFORMATION >
: Apply lithium-based grease including molybdenum disulphide.
Refer to GI-7, "Component" for symbols not described on the above.

RHD models

PCIB2042E

1. Clutch pedal assembly 2. Assist spring 3. Bushing

4. Clevis pin 5. Bushing 6. Stopper rubber
7. Pedal pad 8. Pedal stopper bolt (Without ASCD) 9. ASCD clutch switch (With ASCD)
10. Stopper rubber 11. Snap pin
: Apply lithium-based grease including molybdenum disulphide.
Refer to GI-7, "Component" for symbols not described on the above.

INSTALLATION
When installing clutch pedal, refer to the following.
NOTE:
Tighten pedal stopper bolt lock nut (without ASCD) or ASCD clutch switch lock nut (with ASCD) to the speci-
fied torque after installing clutch pedal assembly in vehicle and adjusting the pedal free play.

Revision: 2007 September CL-6 D40

 CLUTCH FLUID
< SERVICE INFORMATION >
CLUTCH FLUID
A
Air Bleeding Procedure INFOID:0000000002978310

NOTE: B
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all the air from the system.
CAUTION:
• Monitor clutch fluid level in reservoir tank to make sure it does not empty. CL
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
• Bleed air for clutch connector first, and then for operating cylinder. D
(For YD engine of LHD models)
1. Fill reservoir tank with new clutch fluid.
2. Connect a transparent vinyl hose to air bleeder valve.
3. Depress clutch pedal slowly and fully several times at an interval E
of 2 to 3 seconds and hold it.
4. With clutch pedal depressed, open air bleeder valve to release
air. F
5. Close air bleeder valve.
6. Release clutch pedal and wait for 5 seconds.
7. Repeat steps 3 to 6 until no bubbles can be observed in clutch
fluid.
PCIB1797E G

8. Tighten air bleeder valve to the specified torque. Refer to CL-11,

"Removal and Installation" and CL-10, "Removal and Installa- H
tion".

PCIB1390E
K

Revision: 2007 September CL-7 D40

 CLUTCH MASTER CYLINDER
< SERVICE INFORMATION >
CLUTCH MASTER CYLINDER
Component INFOID:0000000002978311

PCIB1388E

1. Nipple 2. Clamp 3. Hose

4. Cylinder body 5. Dust cover 6. Clevis
7. Clevis pin 8. Snap pin 9. Stopper ring
10. Stopper 11. Push rod 12. Piston assembly
13. Return spring 14. Seal 15. Spring pin

Removal and Installation INFOID:0000000002978312

REMOVAL
Refer to the figure for clutch master cylinder removal procedure.
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
INSTALLATION
Note the following, and install in the reverse order of removal.
• Check the positions of clevis and push rod. If measurement is out-
side the standard length, adjust the positions of clevis and push
rod.

Length “L”
5M/T models
LHD models : 119.0 - 120.0 mm (4.69 - 4.72 in)
RHD models : 109.5 - 110.5 mm (4.31 - 4.35 in)
6M/T models
SCIA5158E
QR25DE engine models
LHD models : 119.0 - 120.0 mm (4.69 - 4.72 in)
YD25DDTi engine models
LHD models : 121.0 - 122.0 mm (4.76 - 4.80 in)
RHD models : 111.3 - 112.3 mm (4.38 - 4.42 in)

Revision: 2007 September CL-8 D40

 CLUTCH MASTER CYLINDER
< SERVICE INFORMATION >
Disassembly and Assembly INFOID:0000000002978313

A
DISASSEMBLY
• Loosen push rod lock nut then remove clevis and lock nut, if necessary.
NOTE: B
Clutch pedal height is controlled with position of clevis and push rod.
• Remove stopper ring and stopper. Remove push rod from cylinder body while holding it securely to prevent
piston assembly popping out. CL
CAUTION:
Restrain the push rod while doing this because there is a danger the piston assembly will fly out of
the cylinder body.
D
ASSEMBLY
• Apply rubber lubricant to the internal surface of cylinder body, the sliding surface of piston assembly, and
piston cup of piston assembly.
CAUTION: E
Restrain the push rod while doing this because there is a danger the piston assembly will fly out of
the cylinder body.
• Check and adjust the positions of clevis and push rod. After adjust- F
ing “L”, tighten lock nut to the specified torque. Refer to CL-8,
"Component".
G
Length “L”
5M/T models
LHD models : 119.0 - 120.0 mm (4.69 - 4.72 in) H
RHD models : 109.5 - 110.5 mm (4.31 - 4.35 in)
6M/T models
QR25DE engine models SCIA5158E I

LHD models : 119.0 - 120.0 mm (4.69 - 4.72 in)

YD25DDTi engine models J
LHD models : 121.0 - 122.0 mm (4.76 - 4.80 in)
RHD models : 111.3 - 112.3 mm (4.38 - 4.42 in)
K

Revision: 2007 September CL-9 D40

 OPERATING CYLINDER
< SERVICE INFORMATION >
OPERATING CYLINDER
Component INFOID:0000000002978314

PCIB1897E

1. Dust cover 2. Push rod 3. Piston assembly

4. Piston cup 5. Piston spring 6. Air bleeder valve
7. Clutch hose 8. Copper washer 9. Cylinder body
R: Apply rubber grease.
r: Apply rubber lubricant.
Refer to GI-7, "Component" for symbols not described on the above.

Removal and Installation INFOID:0000000002978315

REMOVAL
Refer to the figure for operating cylinder removal procedure.
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.

Revision: 2007 September CL-10 D40

 CLUTCH PIPING
< SERVICE INFORMATION >
CLUTCH PIPING
A
Removal and Installation INFOID:0000000002978316

QR25DE models B

CL

PCIB2039E E

1. Clutch tube 2. Lock plate 3. Clutch hose

4. Operating cylinder 5. Master cylinder 6. Clutch pedal
F
Refer to GI-7, "Component" for the symbols in the figure.

YD25DDTi, 5M/T with LHD models

G

PCIB2040E

J
1. Clutch tube 2. Clutch connector 3. Lock plate
4. Clutch hose 5. Operating cylinder 6. Air bleeder valve
7. Master cylinder 8. Clutch pedal
K
Refer to GI-7, "Component" for the symbols in the figure.

YD25DDTi, 5M/T with RHD models

L

PCIB2039E

O
1. Clutch tube 2. Lock plate 3. Clutch hose
4. Operating cylinder 5. Master cylinder 6. Clutch pedal
Refer to GI-7, "Component" for the symbols in the figure.
P

Revision: 2007 September CL-11 D40

 CLUTCH PIPING
< SERVICE INFORMATION >
YD25DDTi, 6M/T with LHD models

PCIB2038E

1. Clutch tube 2. Clutch orifice 3. Clutch connector

4. Lock plate 5. Clutch hose 6. Operating cylinder
7. Air bleeder valve 8. Master cylinder 9. Clutch pedal
Refer to GI-7, "Component" for the symbols in the figure.

YD25DDTi, 6M/T with RHD models

PCIB1898E

1. Clutch tube 2. Clutch orifice 3. Lock plate

4. Clutch hose 5. Operating cylinder 6. Master cylinder
7. Clutch pedal
Refer to GI-7, "Component" for the symbols in the figure.

REMOVAL
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.

Revision: 2007 September CL-12 D40

 CLUTCH RELEASE MECHANISM
< SERVICE INFORMATION >
CLUTCH RELEASE MECHANISM
A
Removal and Installation INFOID:0000000002978317

COMPONENTS B
5M/T models
CL

JPDIB0072ZZ
H
1. Retainer spring 2. Withdrawal lever 3. Dust cover
4. Release bearing
: Apply lithium-based grease including molybdenum disulphide. I
Refer to GI-7, "Component" for symbols not described on the above.

6M/T models J

PCIB1615E

Revision: 2007 September CL-13 D40

 CLUTCH RELEASE MECHANISM
< SERVICE INFORMATION >

1. Holder spring 2. Release bearing sleeve 3. Release bearing

4. Snap spring 5. Dust cover 6. Withdrawal lever

REMOVAL
Refer to the figure for release bearing and withdrawal lever removal procedure.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
• Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage to
the clutch may result. Excessive grease may cause slip or judder. Wipe off any grease oozing from
the parts.
• Be careful not to bring any grease to the clutch disk facing, pressure plate surface and flywheel sur-
face.
1. Install release bearing to release bearing sleeve using the drift
[SST: KV30101400]. (For 6M/T models)
CAUTION:
Press bearing inner race by pushing with the drift.

PCIB0275E

2. Following the instructions below, apply grease to the specified points.

5M/T models

SCL815

6M/T models

PCIB1393E

CAUTION:
Wipe off any old grease, debris, or powdery residue left on the grease applying surfaces.
• Evenly apply approximately 1 mm (0.04 in) thick coating of recommended grease to withdrawal lever
and release bearing sliding surface.
• Apply recommended grease to withdrawal lever ball pin contact surface and inner slots of release bear-
ing sleeve. The grease surface should be level with the surrounding area.

Revision: 2007 September CL-14 D40

 CLUTCH RELEASE MECHANISM
< SERVICE INFORMATION >
• Apply a thin coat of recommended grease evenly to release bearing sleeve sliding surface of front
cover. Install release bearing sleeve assembly to front cover. Wipe off any excess grease that oozes A
from the parts and then remove release bearing sleeve assembly.
3. To install, reverse the removal procedure, following the cautions below. (For 6M/T models)
CAUTION: B
• Before installing manual transmission to the vehicle, make sure that each sliding surface slides
smoothly by operating withdrawal lever.
• When assembling, make sure that both ends of snap
spring touch the end face of withdrawal lever. CL
• Be careful with the orientation snap spring.

SCIA6903E
F

Revision: 2007 September CL-15 D40

 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
< SERVICE INFORMATION >
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Removal and Installation INFOID:0000000002978318

COMPONENTS

PCIB1394E

1. Flywheel 2. Clutch disc 3. Clutch cover

CAUTION:
• Be careful not to bring any grease to the clutch disc facing, pressure plate surface and flywheel sur-
face.
• If the flywheel is removed, align the dowel pin with smallest hole of flywheel.
REMOVAL
Refer to the figure for clutch cover and clutch disc removal procedure.
INSPECTION AND ADJUSTMENT AFTER REMOVAL
Flywheel Runout
Measure the runout at the flywheel clutch contact surface using a
dial indicator. If runout is outside the specification, replace flywheel.
If a trace of burn or discoloration is found on the surface, repair it
with sandpaper.

Allowable flywheel runout

QR25DE engine models
YD25DDTi engine mod-
els
: Refer to EM-93, "Inspec-
tion After Disassembly".
: Refer to EM-183, "Stan-
dard and Limit".
PBIC2646E

CAUTION:
Measure it at flywheel outer face (not on knock pin and clutch cover mounting hole).
INSTALLATION
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage to
the clutch may result. Excessive grease may cause slip or judder. Wipe off any grease oozing from the
parts.

Revision: 2007 September CL-16 D40

 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
< SERVICE INFORMATION >
When installing clutch disc and clutch cover, refer to the following.
1. Install clutch disc using a clutch aligner [Commercial service A
tool].
2. Install clutch cover. Pre-tighten clutch cover mounting bolts.
3. Tighten clutch cover mounting bolts evenly in two steps in the B
order shown in the figure. Refer to "COMPONENTS".

CL

PCIB1772E

Revision: 2007 September CL-17 D40

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION >
SERVICE DATA AND SPECIFICATIONS (SDS)
Clutch Control System INFOID:0000000002978319

Type of clutch control Hydraulic

Clutch Master Cylinder INFOID:0000000002978320

Inner diameter 15.87 mm (5/8 in)

Clutch Operating Cylinder INFOID:0000000002978321

Inner diameter 19.05 mm (3/4 in)

Clutch Disc INFOID:0000000002978322

Engine type QR25DE YD25DDTi

Transmission
Facing size (outer dia. × inner dia. ×
thickness)
Wear limit (depth to rivet head)
Runout limit/diameter of the area to be
measured
Maximum backlash of spline (at outer
disc edge)
6M/T 5M/T
240 mm × 160 mm × 3.5 mm 240 mm × 160 mm × 3.2 mm
(9.45 in × 6.30 in × 0.138 in) (9.45 in × 6.30 in × 0.126 in)
0.3 mm (0.012 in)
0.7 mm (0.028 in) / 230 mm (9.06 in) dia.
1.0 mm (0.039 in)
6M/T
250 mm × 160 mm × 3.2 mm
(9.84 in × 6.30 in × 0.126 in)
1.0 mm (0.039 in) / 240 mm
(9.45 in) dia.

Clutch Cover INFOID:0000000002978323

Engine type QR25DE YD25DDTi

Transmission 6M/T 5M/T 6M/T
Set-load 5,890 N (600.8 kg, 1,324 lb) 7,360 N (750.7 kg, 1,655 lb) 9,780 N (997.6 kg, 2,199 lb)
37.0 - 39.0 mm (1.457 -
Diaphragm spring lever height 39.5 - 41.5 mm (1.555 - 1.634 in)
1.535 in)
Uneven limit of diaphragm spring toe height 0.7 mm (0.028 in) or less

Revision: 2007 September CL-18 D40