clutch release bearing 31230-60241 31230-60230 31230-60240 BT-128 68SCRN54PQ-2-F 315 1654 215 J2402042 315 1654 240 3121060230 3125035451 FOR Toyota

1. Pre-installation Preparation: Lift the vehicle to an appropriate height. Prepare professional disassembly tools, a new clutch release bearing, a torque wrench, and other necessary tools. Ensure the release bearing is clean, free of rust-preventive grease and debris.
2. Install the Release Fork Bushing: Use a special tool to press the release fork bushing into the transmission case.
3. Install the Release Fork Shaft: Attach the return spring to the left end of the release fork shaft, then insert the left end into the left hole of the transmission case first, followed by inserting the right end into the right bushing hole. Subsequently, install the left release fork shaft bushing and bushing seat. Apply sealant to the gasket and guide sleeve, mount them on the front of the transmission case, and tighten the bolts to a torque of 15N·m. Tighten the bolt at the rear of the transmission case to 15N·m to lock the release fork shaft. Verify that the release fork shaft rotates flexibly without left-right movement.
4. Press-fit the Release Bearing: Use a special tool to vertically press the release bearing into the release bearing housing.
5. Install the Clutch Driven Disc and Pressure Plate Assembly: Place the driven disc on the engine flywheel with the protruding side of the damping springs facing outward, and position it using a centering rod. Mount the pressure plate assembly, then tighten the bolts at intervals with a torque wrench to a torque of 25N·m (follow a diagonal sequence for even force distribution).
6. Lubricate Relevant Components: Apply an appropriate amount of high-temperature grease to the ball pins of the clutch release levers, the tips of the release levers, and the contact area between the release bearing and the release fork.
7. Assemble the Release Bearing and Release Fork: Install the lubricated release bearing onto the release fork, ensuring it fits securely into the fork's grooves or is fastened with retaining clips.
8. Subsequent Reinstallation: Reattach the transmission and other components in the reverse order of disassembly.
9. Adjust the Clutch: Adjust the clutch pedal free travel to the standard range of 5-15mm. To adjust, loosen the lock nut, rotate the push rod until the desired free travel is achieved, then retighten the lock nut.

1. Component Inspection

• Check Bearing Quality: Ensure the clutch release bearing is free of damage, deformation, and rotates flexibly. Defects in the bearing may cause abnormal clutch operation, such as abnormal noise, jamming, or other issues.

• Inspect Other Relevant Components: Simultaneously check for wear, damage, or other faults in related components like the clutch pressure plate and clutch disc. Replace faulty parts promptly to avoid affecting the overall performance of the clutch system.

2. Installation Process

• Maintain Cleanliness: Keep the work area clean and tidy to prevent debris from entering the clutch system. Clean the installation site to remove oil stains and impurities before installation, as these foreign objects can impair the normal operation and service life of the release bearing.

• Use Proper Tools: Utilize special tools during installation (e.g., a dedicated tool for pressing the release bearing into place). Avoid direct impact with hard objects like hammers to prevent bearing damage.

• Ensure Correct Installation Direction: The release bearing has a specific installation orientation and must be installed in accordance with the vehicle’s repair manual. For example, when fitting the release bearing onto the release sleeve in certain models, ensure proper alignment of its grooves or retaining clips.

• Lubricate Relevant Parts: Apply an appropriate amount of high-temperature grease to the surface of the release bearing, the ball pins of the release levers, the tips of the release levers, and the contact area between the release bearing and the release fork to reduce friction and wear.

• Follow Installation Sequence: When installing the clutch pressure plate assembly, use a centering tool or the transmission input shaft for centering to ensure coaxiality between the driven disc and the pressure plate (facilitating input shaft installation). Fasten the pressure plate bolts only after the pressure plate is fully in contact with the flywheel, tightening them sequentially in a diagonal pattern to ensure secure mounting and uniform force distribution.

3. Post-Installation Inspection

• Verify Installation Position: After installation, check that the release bearing is correctly positioned and that the release fork moves flexibly without jamming or loosening.

• Adjust Clutch Pedal Travel: Adjust the clutch pedal free travel to match the vehicle’s technical specifications. For instance, the standard free travel for the clutch pedal in some Toyota models is 5-15mm, ensuring normal clutch engagement and disengagement.

• Test Drive Inspection: Start the vehicle and perform several gear shifts to check the clutch operation. Confirm there are no abnormal noises or jolts; troubleshoot and resolve any issues promptly if detected.

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