Toyota 31204-20100 Fork Sub-Assy, Clutch Release

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The procedure for removal applies to 2009 and earlier models only, as 2010 and later models have the clutch release bearing and release cylinder as a single assembly that cannot be replaced separately. Begin by disconnecting the negative cable from the battery. Next, remove the transaxle. Reach behind the clutch fork to disengage it from the ballstud by pulling on the retention spring, then remove the fork and bearing. For inspection, hold the bearing by the outer race and rotate the inner race while applying pressure; it should turn smoothly. If it does not, replace the bearing/hub assembly. Wipe the bearing with a clean rag and inspect for damage, wear, and cracks, avoiding immersion in solvent as it is sealed for life. Also, check the clutch fork for any cracks and bends. For installation, fill the inner groove of the release bearing with high-temperature grease and apply a light coat of the same grease to the transaxle input shaft splines and the sleeve of the transaxle front bearing retainer. Lubricate the clutch fork ball socket, fork ends, and release cylinder pushrod socket with high-temperature grease. Attach the release bearing to the clutch fork, then slide the release bearing onto the transaxle input shaft front bearing retainer while passing the end of the clutch fork through the opening in the clutch housing. Push the clutch fork onto the ball stud until it is firmly seated, and apply a light coat of high-temperature grease to the face of the release bearing where it contacts the pressure plate diaphragm fingers. The remainder of the installation follows the reverse order of removal.

To remove the clutch parts and Clutch Fork while leaving the engine in the vehicle, start by removing the Clutch Slave Cylinder, and the transaxle from the vehicle while supporting the engine. Next, inspect the flywheel and pressure plate for indexing marks and gradually loosen the pressure plate-to-flywheel bolts in a diagonal pattern. Then, remove the bolts, pressure plate, and clutch disc. After, check the flywheel for cracks and damage, and the clutch disc for wear and loose rivets. At that moment, check the pressure plate for damage and replace or resurface it. The installation procedure starts by having a clean surface on both the flywheel and pressure plate. Use an alignment tool to properly position the clutch disc and pressure plate, and then secure the bolts. After that, you can use high-temperature grease to lubricate the release bearing before installing it as well as the transaxle. Finally, install the remainder of the components and torque down the fasteners to the proper specifications.

Attach the release bearing to the release lever.

Before reinstalling the transaxle, you should apply a light coat of high-temperature grease to the face of the release bearing where it contacts the pressure plate diaphragm fingers.

Hold the bearing by the outer race and rotate the inner race while applying pressure. The bearing should turn smoothly; if it doesn't, replace it.