CL–1

CLUTCH – TROUBLESHOOTING

TROUBLESHOOTING
CL026–02

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.
Symptom Suspect Area See page
11.Engine mounting (Loose) –
12.Clutch disc (Runout is excessive) CL–18
13.Clutch disc (Oily) CL–16
Clutch grabs/chatters 14.Clutch disc (Worn out) CL–16
15.Clutch disc (Damaged torsion rubber) CL–18
16.Clutch disc (Glazed) CL–16
17.Diaphragm spring (Out of tip alignment) CL–20
1. Clutch line (Air in line) –
Clutch pedal spongy 2. Master cylinder piston cup (Damaged) CL–6
3. Release cylinder piston cup (Damaged) CL–11
1. Release bearing (Worn, dirty or damaged) CL–16
Clutch noisy 2. Input shaft bearing (Worn, dirty or damaged) –

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3. Clutch disc (Damaged torsion rubber) CL–18
1. Clutch pedal (Freeplay out of adjustment) CL–2
2. Clutch disc (Oily) CL–20
3. Clutch disc (Worn out) CL–16
Clutch slips
4. Diaphragm spring (Damaged) CL–16
5. Pressure plate (Distortion) CL–16
6. Flywheel (Distortion) –

1. Clutch pedal (Freeplay out of adjustment) CL–2

2. Clutch line (Air in line) –
3. Master cylinder piston cup (Damaged) CL–6
4. Release cylinder piston cup (Damaged) CL–11
5. Input shaft bearing (Worn, dirty or damaged) –
6. Clutch disc (Out of true) CL–16
7. Clutch disc (Runout is excessive) CL–18
Clutch does not disengage
8. Clutch disc (Lining broken) CL–16
9. Clutch disc (Dirty or burred) CL–16
10.Clutch disc (Oily) CL–16
11.Clutch disc (Lack of spline grease) CL–20
12.Diaphragm spring (Damaged) CL–16
13.Diaphragm spring (Out of tip alignment) CL–20
14.Pressure plate (Distortion) CL–16

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1506

CL–2
CLUTCH – CLUTCH PEDAL

CLUTCH PEDAL CL027–02

w/o Cruise Control System:
Stopper Bolt
INSPECTION
1. CHECK THAT PEDAL HEIGHT IS CORRECT
Pedal height from dash panel:
160.1 – 170.1 mm (6.303 – 6.697 in.)
Pedal height from dash insulator:
155.1 – 165.1 mm (6.106 – 6.500 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Loosen the lock nut and turn the stopper bolt or clutch
Clutch Start Switch start switch until the height is correct.
(b) Tighten the lock nut.

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Pedal Height
Adjust Point
Pedal Height

Push Rod Play

D06511

3. CHECK THAT PEDAL FREEPLAY AND PUSH ROD

PLAY ARE CORRECT
(a) Push in on the pedal until the beginning of clutch resis-
tance is felt.
Pedal freeplay: 5.0 – 15.0 mm (0.197 – 0.591 in.)
(b) Gently push on the pedal until the resistance begins to in-
crease a little.
Push rod play at pedal top:
Pedal Freeplay
CL0102 1.0 – 5.0 mm (0.039 – 0.197 in.)
4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND
PUSH ROD PLAY
(a) Remove the lower finish panel and disconnect the air
duct.
(b) Loosen the lock nut and turn the push rod until the free-
play and push rod play are correct.
(c) Tighten the lock nut.
(d) After adjusting the pedal freeplay, check the pedal height.
(e) Connect the air duct and install the lower finish panel.

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1507

 CL–3
CLUTCH – CLUTCH PEDAL

5. CHECK 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 reverse position until the gears contact.

(d) Gradually depress the clutch pedal and measure the

stroke from where the gear noise stops (release point) up
to the full stroke end position.
25 mm (0.98 in.) or more Standard distance:
Release 25 mm (0.98 in.) or more
Point
(From pedal stroke end position to release point)
If the distance is not as specified, perform the following opera-

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Full Stroke tion.
End Position
CL0512
Check pedal height.

Check push rod play and pedal freeplay.

Bleed clutch line.

Check clutch cover and disc.

6. 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, replace the clutch start switch.

Clutch
Start Switch

Q02465

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1508

CL–4
CLUTCH – CLUTCH PEDAL

7. CHECK CONTINUITY OF CLUTCH START SWITCH

(a) Disconnect the connector.
(b) Remove the nut and clutch start switch from the clutch
Ohmmeter pedal bracket.
(c) Check the continuity between terminals when the switch
is ON and OFF.
Switch position Condition
ON (pushed) Continuity
D00904
OFF (free) No Continuity
If the continuity is not as specified, replace the switch.
(d) Install the clutch start switch to the clutch pedal bracket
with the nut.
(e) Connect the connector.

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8. CHECK CONTINUITY OF CLUTCH START CANCEL
SWITCH
(a) Remove the switch base (See page BO–72).
(b) Remove the clutch start cancel switch from the switch
base.

D04403

(c) Check that no continuity exists between terminals 1 and

3.
1 If the continuity is not as specified, replace the clutch start can-
cel switch.

3 D04404

9. CHECK OPERATION OF CLUTCH START CANCEL

1 SWITCH
(a) Connect the positive (+) lead from the battery to terminal
7 7 and connect negative (–) lead to terminal 5.
(b) Check that no continuity exists between terminals 1 and
3 3.

D04405

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1509

 CL–5
CLUTCH – CLUTCH PEDAL

5 (c) When pushing the switch, check that the indicator light
1 connector and continuity exists between terminal 1 and
3.

7 3

D04406

(d) Check that no continuity exists between terminals 1 and

5
1 3 when the battery lead is disconnected.
If the continuity is not as specified, replace the clutch start can-
cel switch.
7 3

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D04407

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1510

CL–6
CLUTCH – CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER

CL028–02

COMPONENTS

Clip
Filler Cap Clevis
Snap Ring
Slotted
Float
Spring Pin Boot
Reservoir Tank
Piston

Gasket

Lock Nut Wave

Grommet
Washer
Master Cylinder
Spring Washer Pin
Body

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Push Rod
14 (143, 10)

15 (155, 11)

12 (120, 9)
Clutch Line

N·m (kgf·cm, ft·lbf) : Specified torque

Non–reusable part
Lithum soap base glycol grease D04401

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1511

 CL–7
CLUTCH – CLUTCH MASTER CYLINDER
CL082–01

REMOVAL
1. REMOVE FILLER CAP AND FIOAT FROM RESERVOIR
2. DRAW OUT BRAKE FLUID WITH SYRINGE
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.

3. DISCONNECT CLUTCH LINE FROM MASTER CYL-

INDER
Using SST, disconnect the line. Use a container to catch the
fluid.
SST 09023–00100
4. REMOVE CLIP AND CLEVIS PIN
SST (a) Using needle–nose pliers, remove the clip.

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(b) Remove the clevis pin and wave washer.
D06510

5. REMOVE 2 MOUNTING NUTS AND PULL OUT MAS-

TER CYLINDER
6. REMOVE GASKET

D04399

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1512

CL–8
CLUTCH – CLUTCH MASTER CYLINDER
CL02A–02

DISASSEMBLY
1. REMOVE RESERVOIR TANK
(a) Using a pin punch and hammer, drive out the slotted
spring pin.
(b) Remove the reservoir and grommet.
2. REMOVE CLEVIS AND BOOT
(a) Loosen the lock nut to remove the clevis and remove the
lock nut.
D04400
(b) Remove the boot.

3. REMOVE PUSH ROD

(a) While pushing the push rod, using snap ring pliers, re-
move the snap ring.
(b) Remove the push rod and washer.
4. REMOVE PISTON WITH SPRING

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Q02470

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1513

 CL–9
CLUTCH – CLUTCH MASTER CYLINDER
CL083–01

REASSEMBLY
1. COAT PARTS WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
2. INSERT PISTON WITH SPRING INTO CYLINDER

Z08053

3. INSTALL PUSH ROD AND BOOT

(a) Install the washer to the push rod.
(b) Push the push rod into the piston, using snap ring pliers,
install the snap ring.
(c) Install the boot.
4. TEMPORARILY INSTALL LOCK NUT AND CLEVIS

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Q02470

5. INSTALL RESERVOIR
(a) Install the reservoir and a new grommet.
(b) Using a pin punch and hammer, drive in the slotted spring
pin.

Protrusion
1.5 – 3.5 mm
(0.059 – 0.138 in.)

Q02471

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1514

CL–10
CLUTCH – CLUTCH MASTER CYLINDER
CL084–01

INSTALLATION
1. INSTALL NEW GASKET

2. INSTALL MASTER CYLINDER WITH 2 MOUNTING

NUTS
Torque: 14 N·m (143 kgf·cm, 10 ft·lbf)

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D04399

3. CONNECT CLUTCH LINE TO MASTER CYLINDER

Using SST, connect the clutch line.
SST 09023–00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
4. INSTALL CLEVIS PIN, WAVE WASHER AND CLIP
5. FILL CLUTCH RESERVOIR WITH BRAKE FLUID AND
SST BLEED CLUTCH SYSTEM
6. ADJUST CLUTCH PEDAL (See page CL–2)
D06510 7. CHECK FOR LEAKS

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1515

 CL–11
CLUTCH – CLUTCH RELEASE CYLINDER

CLUTCH RELEASE CYLINDER

CL02D–02

COMPONENTS

Bleeder Plug Push Rod

11 (110, 8)
Boot
Clutch Line
15 (155, 11) 12 (120, 9)

Piston
Release Cylinder Body Spring
N·m (kgf·cm, ft·lbf) : Specified torque
Q07554
Lithum soap base glycol grease D05008

cardiagn.com

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1516

CL–12
CLUTCH – CLUTCH RELEASE CYLINDER
CL02E–02

REMOVAL
1. REMOVE FILLER CAP AND FIOAT FROM RESERVOIR
2. DRAW OUT BRAKE FLUID WITH SYRINGE
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.

3. DISCONNECT CLUTCH LINE FROM RELEASE CYL-

SST
INDER
Using SST, disconnect the line. Use a container to catch the
fluid.
SST 09023–00100

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Z17113

4. REMOVE 2 BOLTS AND PULL OUT RELEASE CYL-

INDER

Q06733

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1517

 CL–13
CLUTCH – CLUTCH RELEASE CYLINDER
CL02F–02

DISASSEMBLY
1. REMOVE BOOT AND PUSH ROD
(a) Pull out the boot with the push rod.
(b) Remove the boot from the push rod.

2. REMOVE PISTON AND SPRING

Using compressed air, remove the piston with the spring from
the cylinder.
NOTICE:

Blowing off the air may cause the piston’s jump–out.
When removing the piston, hold it with your hand us-
ing a waste cloth.

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Take care not to splash brake fluid when air–blowing.
Q02475 3. REMOVE BLEEDER PLUG

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1518

CL–14
CLUTCH – CLUTCH RELEASE CYLINDER
CL02G–02

REASSEMBLY
1. INSTALL BLEEDER PLUG
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)

2. COAT PISTON WITH LITHIUM SOAP BASE GLYCOL

GREASE, AS SHOWN
3. INSTALL PISTON AND SPRING INTO CYLINDER
4. INSTALL BOOT AND PUSH ROD
(a) Install the push rod to the boot.
(b) Install the boot with the push rod to the cylinder.

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Z07291

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1519

 CL–15
CLUTCH – CLUTCH RELEASE CYLINDER
CL085–01

INSTALLATION
1. INSTALL RELEASE CYLINDER WITH 2 BOLTS
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

Q06733

2. CONNECT CLUTCH LINE TO RELEASE CYLINDER

SST Using SST, connect the clutch line.
SST 09023–00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
3. FILL CLUTCH RESERVOIR WITH BRAKE FLUID AND
BLEED CLUTCH SYSTEM
4. CHECK FOR LEAKS

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Z17113

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1520

CL–16
CLUTCH – CLUTCH UNIT

CLUTCH UNIT
CL02I–02

COMPONENTS

85 (850, 63)

Pilot Bearing

Clutch Disc
Clutch Cover

Clutch Release Bearing

Clip
Flywheel

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85 (850, 63)

19 (195, 14)

Clutch Release
N·m (kgf·cm, ft·lbf) : Specified torque Fork

Non–reusable part Boot
Clutch Release
Clutch spline grease Fork Support
Release hub grease
47 (480, 35)
D04402

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1521

 CL–17
CLUTCH – CLUTCH UNIT
CL02J–02

REMOVAL
Matchmarks 1. REMOVE TRANSMISSION FROM ENGINE
R150 (2WD): See page MT–3
R150F (4WD): See page MT–8
2. REMOVE CLUTCH COVER AND CLUTCH 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.
Q06639
(c) Remove the set bolts, and pull off the clutch cover with the
clutch disc.
NOTICE:
Do not drop the clutch disc.

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3. REMOVE BOOT, CLUTCH RELEASE BEARING AND
CLUTCH RELEASE FORK FROM TRANSMISSION
(a) Remove the boot and release bearing together with the
fork.
(b) Remove the clip from the release bearing.

Q06637

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1522

CL–18
CLUTCH – CLUTCH UNIT
CL02K–03

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.

CL0239

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.

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CL0373

3. INSPECT FLYWHEEL RUNOUT

Using a dial indicator with roller instrument, check the flywheel
runout.
Maximum runout: 0.1 mm (0.004 in.)
If necessary, replace the flywheel.

Q07250

4. INSPECT PILOT BEARING

Turn the bearing by hand while applying force in the rotation
direction.
If the bearing sticks or has much resistance, replace the pilot
bearing.
HINT:
The bearing is permanently lubricated and requires no cleaning
or lubrication.
Q02481

5. IF NECESSARY, REPLACE PILOT BEARING

SST (a) Remove the 2 bolts at diametrically opposite points.
(b) Using SST, remove the pilot bearing.
SST 09303–35011

Q02482

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1523

 CL–19
CLUTCH – CLUTCH UNIT

(c) Using SST and a hammer, install a new pilot bearing.

SST
SST 09304–30012
HINT:
After assembling the pilot bearing to the hub, make sure that it
rotates smoothly.
(d) Install and torque 2 new bolts.
Torque: 85 N·m (850 kgf·cm, 63 ft·lbf)

Q02483

6. INSPECT DIAPHRAGM SPRING FOR WEAR

Using calipers, measure the diaphragm spring for depth and
width of wear.
Maximum
B
Depth A: 0.6 mm (0.024 in.)
A Width B: 5.0 mm (0.197 in.)
If necessary, replace the clutch cover.

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Z10062

7. INSPECT CLUTCH 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.

N00414

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1524

CL–20
CLUTCH – CLUTCH UNIT
CL02L–02

INSTALLATION
1. INSTALL CLUTCH DISC AND CLUTCH COVER ON
FLYWHEEL
Flywheel SST (a) Insert SST in the clutch disc, then insert them in the fly-
Side
wheel.
SST 09301–00110
HINT:
Q06647
Take care not to insert the clutch disc in the wrong direction.
D05010

(b) Align the matchmarks on the clutch cover and flywheel.

5 1
Matchmarks (c) Following the procedures shown in the illustration, tighten
the 6 bolts in the order starting from the bolt locating near
3 the knock pin on the top.
4 Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
HINT:

Following the order in the illustration, tighten the bolts at

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6 2 a time evenly.
Q06958
Shake SST up and down, right and left lightly, after check-
ing that the disc is in the center, tighten the bolts.
2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the dia-
phragm spring tip alignment.
Maximum non–alignment: 0.5 mm (0.020 in.)
If alignment is not as specified value, using SST, adjust the dia-
phragm spring tip alignment.
SST 09333–00013
SST
Q06641

3. APPLY RELEASE HUB GREASE

Apply release hub grease to the release fork and hub contact,
release fork and push rod contact and release fork pivot points.
Sealant:
Part No. 08887–01806, RELEASE HUB GREASE or
equivalent

Z00762

4. APPLY CLUTCH SPRING GREASE

Apply clutch spline grease to the input shaft spline.
Sealant:
Part No. 08887–01706, CLUTCH SPLINE GREASE or
equivalent
5. INSTALL BOOT, CLUTCH RELEASE BEARING AND
CLUTCH RELEASE FORK TO TRANSMISSION
(a) Install the clip to the release bearing.
Q06642 (b) Install the boot and release bearing to the release fork,
and then install them to the transmission.
2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1525

 CL–21
CLUTCH – CLUTCH UNIT

6. INSTALL TRANSMISSION TO ENGINE

R150 (2WD): See page MT–6
R150F (4WD): See page MT–11

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2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1526