M/T - Clutch Slipping In All Gears
T-SB-0385-09Rev1
November 23, 2009
6-Speed Manual Transmission Clutch Difficult Engaging
Service Category
Drivetrain
Section
Clutch
Market
USA
Applicability
TSB REVISION NOTICE
March 12, 2010 Rev1:
^ Applicable Warranty has been updated.
Any previous printed versions of this service bulletin should be discarded.
Introduction
Some customers of manual transmission equipped V6 FJ Cruiser and Tacoma vehicles may experience a slipping feeling in all forward gears and reverse. The center section of the clutch disk may have separated from the friction material section of the clutch disk. Installation of a new clutch disk and clutch cover (pressure plate) is required to repair the vehicle. Follow the repair procedure in this bulletin to address customer concerns.
Parts Information
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Required Tools & Equipment
Repair Procedure
1. Confirm condition.
Place vehicle in every gear position (forward and reverse) and attempt to move vehicle. Does the vehicle move in any gear?
^ YES - This TSB does NOT apply. Refer to the applicable Repair Manual for diagnosis.
^ NO - Go to step 2.
2. Place vehicle on a lift and raise the vehicle oft the ground with an assistant inside the vehicle.
While watching the propeller shaft assembly have the assistant start the vehicle and shift the vehicle into every gear position while the vehicle is in 2WD.
Does the rear propeller shaft (driveshaft) turn when the vehicle is shifted into any gear position?
^ YES - This TSB does NOT apply. Check rear differential and rear axle assemblies for damage.
^ NO - Go to step 3.
3. Remove the manual transmission assembly to inspect the clutch disk and clutch cover (pressure plate).
Refer to the Technical Information System (TIS) applicable model and model year Repair Manual:
4. Inspect the clutch cover (pressure plate). Does the clutch cover (pressure plate) appear damaged?
^ YES - This TSB does NOT apply. Refer to the applicable Repair Manual for diagnosis.
^ NO - Go to step 5.
5. Remove the clutch cover (pressure plate) and clutch disk assembly.
Refer to TIS applicable model and model year Repair Manual:
6. Inspect the surface condition of the clutch disk friction material.
Does the clutch disk friction material display damage (such as excessive wear tearing of friction material or glazing of friction material?
^ YES - This TSB does NOT apply.
^ NO - Go to next step.
7. Inspect the clutch disk for separation of the center hub from the friction material section.
A. Using one hand grab the center hub of the clutch disk and with the other hand grab the friction material section of the clutch disk.
B. Attempt to turn the friction material section of the clutch disk while holding the center hub.
Can the friction material section of the clutch disk be turned without rotating the center hub section?
^ YES - The center hub of the clutch disk has separated from the friction material section. Continue to step 8.
^ NO - This TSB does NOT apply. Continue diagnosis to isolate the cause of slipping.
HINT
Close inspection of the clutch disk will reveal the area of separation (see Figure 1).
8. Replace the clutch disk and clutch cover (pressure plate) assemblies.
Refer to TIS applicable model and model year Repair Manual:
9. Reinstall the manual transmission assembly.
Refer to TIS applicable model and model year Repair Manual:
10. Test drive vehicle and confirm normal operation.