TOYOTA SUPRA 1997 Service Repair Manual

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

CL-2
- CLUTCHTROUBLESHOOTING
1543 Author
: Date
:
1997 SUPRA (RM502U) Clutch slips
1. Clutch pedal (Freeplay out of adjustment)
2. Clutch disc (Oily)
3. Clutch disc (Worn out)
4. Diaphragm spring (Damaged)
5. Pressure plate (Distortion)
6. Flywheel (Distortion)CL-3
CL-15
CL-20
CL-15
CL-20
CL-15
CL-20
CL-15
CL-20
-
Clutch does not disengage
1. Clutch pedal (Freeplay out of adjustment)
2. Clutch line (Air in line)
3. Master cylinder cup (Damaged)
4. Release cylinder cup (Damaged)
5. Input shaft bearing (Worn, dirty or damaged)
6. Pilot bearing (Worn or damaged)
7. Clutch disc (Out of true)
8. Clutch disc (Runout is excessive)
9. Clutch disc (Lining broken)
10. Clutch disc (Dirty or burred)
11. Clutch disc (Oily)
12. Clutch disc (Lack of spline grease)
13. Diaphragm spring (Damaged)
14. Diaphragm spring (Out of tip alignment)
15. Pressure plate (Distortion)CL-3
-
CL-5
CL-10
-
CL-15
CL-20
CL-15
CL-20
CL-15
CL-20
CL-15
CL-20
CL-15
CL-20
CL-15
CL-20
CL-19
CL-25
CL-15
CL-20
CL-19
CL-25
CL-15
CL-20

CL045-02
CL-10
- CLUTCHCLUTCH RELEASE CYLINDER
1551 Author
: Date
:
1997 SUPRA (RM502U)
CLUTCH RELEASE CYLINDER
COMPONENTS

CL0AB-01
Q01125
Q01126
- CLUTCHCLUTCH RELEASE CYLINDER
CL-1 1
1552 Author
: Date
:
1997 SUPRA (RM502U)
REMOVAL
1. 2JZ - GTE:
REMOVE CLUTCH HOUSING COVER LH
Remove the 2 bolts.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
2. 2JZ - GTE:
DISCONNECT CLUTCH LINE
Using SST, disconnect the clutch line union. Use a container to
catch the fluid.
SST 09023-00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
3. 2JZ - GTE:
REMOVE 2 BOLTS AND PULL OUT RELEASE CYL-
INDER
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
4. 2JZ - GE:
DISCONNECT CLUTCH LINE
Using SST, disconnect the clutch line union. Use a container to
catch the fluid.
SST 09023-00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
5. 2JZ - GE:
REMOVE RELEASE CYLINDER WITH 3 BOLTS
Torque:
Bolt A: 12 N´m (120 kgf´cm, 9 ft´lbf)
Bolt B: 4.9 N´m (50 kgf´cm, 43 in.´lbf)

CL047-01
Q04338
CL-12
- CLUTCHCLUTCH RELEASE CYLINDER
1553 Author
: Date
:
1997 SUPRA (RM502U)
DISASSEMBLY
1. PULL OUT PUSH ROD WITH BOOT
2. REMOVE PISTON WITH SPRING
Using compressed air, remove the piston and spring from the
cylinder.

CL048-01
Z07291
- CLUTCHCLUTCH RELEASE CYLINDER
CL-13
1554 Author
: Date
:
1997 SUPRA (RM502U)
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

CL04A-03
Q06260
Plate Washer
Wave Washer

Snap Ring
Clutch Thrust Cone Spring
Clutch Release Hub
Release Fork Support Clutch DiscClutch Release BearingPlate Washer
Release Fork Support Spring

E-Ring
Release Fork x9

Pilot BearingClutch Cover

Snap Ring
Wave
Washer Flywheel
Assembly
25 (260, 18)
19 (195, 14)
See page CL-22
N´m (kgf´cm, ft´lbf): Specified torque

Non-reusable part
Pin
CL-20
- CLUTCHCLUTCH UNIT (2JZ-GTE)
1561 Author
: Date
:
1997 SUPRA (RM502U)
CLUTCH UNIT (2JZ-GTE)
COMPONENTS

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.

CL04C-02
Q04200
Q04201
Q04202
Q04204
Q04206
CL-22
- CLUTCHCLUTCH UNIT (2JZ-GTE)
1563 Author
: Date
:
1997 SUPRA (RM502U)
INSPECTION
1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using calipers, measure the rivet head depth.
Maximum 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 the runout is excessive, 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 the runout is excessive, replace the flywheel.
4. INSPECT PILOT BEARING
Turn the bearing by hand while applying force in the axial direc-
tion.
If the bearing sticks or has much resistance, replace the pilot
bearing.
5. IF NECESSARY, REPLACE PILOT BEARING
(a) Remove the 2 bolts at the diametrically opposite points.

Q04207
SST
Q04208
SST
Q04206
Q04203
B
A
Q04223
- CLUTCHCLUTCH UNIT (2JZ-GTE)
CL-23
1564 Author
: Date
:
1997 SUPRA (RM502U)
(b) Using SST, remove the pilot bearing.
SST 09303-3501 1
(c) Using SST and a hammer, drive in a new pilot bearing.
SST 09301-001 10
(d) Install 2 new bolts.
(e) First, torque the 2 bolts uniformly a little at a time.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
(f) Then tighten the 2 bolts an additional 80 - 100°.
6. 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.)
Width B: 5.0 mm (0.197 in.)
If necessary, replace the clutch cover.
7. 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 a problem is found, replace the bearing together with the hub.