Rav4 Clutch
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.
| Symptom | Suspect Area | See page |
|---|---|---|
| Clutch grabs/chatters | 3. Engine mounting (Loosen) 4. Clutch disc (Runout is excessive) 5. Clutch disc (Oily) 6. Clutch disc (Worn out) 7. Clutch disc torsion rubber (Damaged) 8. Clutch disc (Glazed) | - CL - 15 CL - 15 CL - 15 CL - 15 CL - 15 |
| 9. Diaphragm spring (Out of tip alignment) | CL - 15 | |
| Clutch pedal spongy | 1. Clutch line (Air in line) | - |
| 2. Master cylinder cup (Damaged) | CL - 5 | |
| 3. Release cylinder cup | CL - 10 | |
| (Damaged) | ||
| 1. Release bearing (Worn, dirty, or damaged) | CL - 15 | |
| 2. Clutch disc torsion rubber (Damaged) | CL - 15 | |
| 2. Clutch disc (Oily) | CL - | |
| 15 | ||
| 3. Clutch disc (Worn out) | CL - 15 | |
| 4. Diaphragm spring (Damaged) | CL - 15 | |
| 5. Pressure plate (Distortion) | CL - 15 | |
| 6. Flywheel (Distortion) | ||
| - | ||
| 1. Clutch pedal (Free play out of adjustment) | CL - 2 | |
| 3. Master cylinder cup (Damaged) | CL - 5 | |
| 4. Release cylinder cup (Damaged) | CL - 10 | |
| 5. Clutch disc (Out of true) | CL - 15 | |
| 6. Clutch disc (Runout is excessive) | CL - 15 | |
| 7. Clutch disc (Lining broken) | CL - 15 | |
| 8. Clutch disc (Dirty or burned) | CL - 15 | |
| 9. Clutch disc (Oily) | CL - 15 CL - 18 | |
| 10.Clutch disc (Lack of spline grease) | CL - 15 | |
| 11.Diaphragm spring (Damaged) | CL - 18 | |
| 12.Diaphragm spring (Out of tip alignment) | ||
| 13.Pressure plate (Distortion) | CL - 15 |
Table Caption: This table lists common clutch symptoms, the suspected underlying causes, and the corresponding page numbers for further troubleshooting.
CL04F -03
CLUTCH PEDAL INSPECTION
- CHECK PEDAL HEIGHT IS CORRECT Pedal height from asphalt sheet:
157.6 -167.6 mm (6.205 -6.598 in.)
- IF NECESSARY, ADJUST PEDAL HEIGHT
Loosen the lock nut and turn the stopper bolt until the height is correct. Tighten the lock nut.
3. CHECK PEDAL FREEPLAY AND PUSH ROD PLAY
- (a) Push in on the pedal until the beginning of clutch resistance 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 increase a little.
Push rod play at pedal top:
1.0 -5.0 mm (0.039 -0.197 in.)
- IF NECESSARY, ADJUST PEDAL FREEPLAY AND PUSH ROD PLAY
- (a) Loosen the lock nut and turn the push rod until the freeplay and push rod play are correct.
- (b) Tighten the lock nut.
- (c) After adjusting the pedal freeplay, check the pedal height.
- (d) Connect the air duct and install the lower finish panel.
5. INSPECT 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 the reverse position until the gears contact.
- (d) 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:
25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance is not as specified.
- /C0083 Inspect pedal height.
- /C0083 Inspect push rod play and pedal freeplay.
- /C0083 Bleed the clutch line.
- /C0083 Inspect the clutch cover and disc.
CL04G -02
1996 RAV4 (RM447U)
6. CHECK CLUTCH START SYSTEM
- (a) Check that the engine does not start when the clutch pedal is released.
- (b) Check that the engine starts when the clutch pedal is fully depressed.
If necessary, replace the clutch start switch.
- CHECK CONTINUITY OF CLUTCH START SWITCH Check the continuity between terminals when the switch is ON and OFF.
| Switch position | Condition |
|---|---|
| ON (pushed) | Continuity |
| OFF (free) | No Continuity |
Table Caption: This table describes the behavior of a switch, indicating that when the switch is in the ON (pushed) position, it allows electrical continuity, while in the OFF (free) position, it breaks continuity.
If continuity is not as specified, replace the switch.
8. CHECK CONTINUITY OF CLUTCH START CANCEL SWITCH
- (a) Check that there is no continuity when connecting the positive (+) lead from the ohmmeter to terminal 2 and the negative ( -) lead to terminal 1.
- (b) Check that there is no continuity when connecting the positive (+) lead from the ohmmeter to terminal 3 and the negative ( -) lead to terminal 1 and 2.
If continuity is not as specified, replace the clutch start cancel switch.
- CHECK OPERATION OF CLUTCH START CANCEL SWITCH
- (a) Connect positive (+) lead from the battery to terminal 3 and negative ( -) lead to terminal 1.
- (b) Check that there is no continuity when connecting the positive (+) lead from the ohmmeter to terminal 2 and the negative ( -) lead to terminal 1.
- (c) When push the switch, check that the indicator light comes on and there is continuity between terminal 1 and 2.
- (d) Check that there is no continuity between terminals 1 and 2 when disconnect the battery lead.
If continuity is not as specified, replace the clutch start cancel switch.
CLUTCH MASTER CYLINDER COMPONENTS
CL04H -02
REMOVAL
- w/ Cruise Control System: REMOVE CRUISE
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