TOYOTA PREVIA 91-97 REPAIR MANUAL

DRIVE TRAIN 7-11

Fig. 35 Grease points of the release fork

Push Rod Play Adjust Point

Pedal Height

Adjust Point

Push Rod Play

90917G53

Fig. 36 Points for clutch pedal adjustments

e. Install the bearing/hub assembly, the fork, the boot and the retain-

ing clip(s) in their original locations.

To install:

7. Inspect the flywheel surface for cracks, heat.scoring (blue marks)
   and warpage. Replace or resurface the flywheel, it any damage is present.

^Before installing any new parts, make sure they are clean. During
installation, do not get grease or oil on any of the components, as
this will shorten clutch life considerably.

8. Using an clutch alignment tool, position the clutch disc against the
   flywheel. The raised center section of the disc faces the transmission.


9. Position the clutch cover onto the flywheel and align the match-
   marks.


10. Install the clutch cover retaining bolts. Tighten the bolts in a criss-
    cross pattern to 14ft. Ibs. (19 Nm).


11. Lubricate the release fork pivot and contact points, release bearing,
    bearing hub and input shaft spline surfaces with a suitable molybdenum
    disulfide lithium based or Multi-purpose grease.


12. Install the boot, release fork, hub, and the bearing assemblies.


13. Install the transmission to the vehicle.


14. Connect the negative battery cable.

ADJUSTMENTS

Pedal Height

I See Figure 36

1. Check the pedal height from the upper surface of the floor panel.
   Standard is between 6.10-6.50 inch (155-165mm). Pushrod play at pedal
   height is 0.04-0.20 inch (1.0-5.Omm).


2. If out of specification, loosen the locknut and turn the stopper bolt
   until the height is correct. Tighten the locknut.


3. Loosen the locknut and turn the pushrod until the pushrod play is
   correct. Tighten the locknut.

Free-Play

» See Figure 37

1. Push in the pedal until the beginning of the clutch resistance is felt.
   Pedal free-play is 0.20-0.59 inch (5.0-15.0mm).


2. To adjust, loosen the locknut and turn the pushrod until the free-play
   and pushrod play are correct.

Pedal Freeplay

Fig. 37 Inspect the pedal height after adjusting the pedal height

3. Tighten the locknut.


4. After adjusting the pedal free play. Check the pedal height.

Release Point

I See Figure 38

1. Pull the parking brake lever and install a wheel stopper.


2. Start the engine and allow to idle.


3. Without depressing the clutch pedal, slowly shift the shift lever from
   reverse position until the gears contact.


4. Gradually depress the clutch pedal and measure the stroke distance
   from the point the gear noise stops (release point) up to the full stroke end
   position. Standard distance is 0.98 inch (25mm) or more.
   '•From the pedal stroke end position to the release point.


5. If the distance is not as specified, perform the following:

• Inspect the pedal height


• Inspect the pushrod play and pedal free-play


• Bleed the clutch line


• Inspect the clutch cover and disc