T-SB-0066-11

~TOYOTA
T-SB-0066-11
Rev1
Technical Service Bulletin
June 28, 2011
5-Speed Manual Transmission Clutch Difficult Engaging
Service
Category
Drivetrain
Section
Clutch
Market
Toyota Supports ~
ASE Certification ~
USA
Applicability
YEAR(S)
MODEL(S)
ADDITIONAL INFORMATION
2005 - 2013
Tacoma
Engine(s): 2TR
Transmission(s) : 5MT
VDS(s): KX22N, NX22N, NX4CN, NX4GN,
NX62N, PX42N, PX4EN , TX22N,TX4CN, TX4GN,
TX62N,UX42N, UX4EN
REVISION NOTICE
June 25, 2013 Rev1:
• Applicability has been updated to include 2012 - 2013 model year vehicles.
Any previous printed versions of this bulletin should be discarded.
Introduction
Some 2005 - 2013 model year Tacoma vehicles equipped with a 5-speed manual transmission may
exhibit a slipping feeling in all forward gears and reverse. Replacement of the clutch disk, clutch
cover, flywheel , and clutch pedal turnover spring is required to repair the vehicle. Follow the repair
procedure in this bulletin to address this condition .
Production Change Information
This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs shown
below.
MODEL
TRANSMISSION
DRIVETRAIN
2WD
Tacoma 5 Speed Manual
4WD
CAB
PRODUCTION CHANGE EFFECTIVE VIN
Regular
5TFNX4CN#DX021603
Access
5TFTX4CN#DX026465
Regular
5TFPX4EN#DX015170
Access
5TFUX4EN#DX018637
© 2013 Toyota Motor Sales, USA
Page 1 of 7
@TOYOTA
T-SB-0066-11
Rev1
June 28, 2011
Page 2 of 7
5-Speed Manual Transmission Clutch Difficult Engaging
Warranty Information
OP CODE
TC9018
TC9019
DESCRIPTION
R & R Clutch Disk, Clutch Cover, Flywheel ,
and Clutch Pedal Turnover Spring
DRIVETRAIN
TIME
2WD
4.1
4WD
4.7
OFP
T1
T2
31250-04090
31250-04091
31250-26230
31250-26231
22
12
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.
Parts Information
PART NUMBER
PART NAME
QTY
31210-35291
Clutch Cover Assembly
1
31250-04090
31250-04091
31250-26230
31250-26231
31250-60500
Clutch Disk Assembly
1
90949-03136
90949-03132
Turnover Spring
1
13405-75060
Flywheel Assembly
1
90910-02116
Flywheel Set Bolt
10
PREVIOUS
NEW
31210-04080
31210-04081
31210-04082
31210-04083
3121 0-04084
31210-26170
31210-26171
31210-26172
© 2013 Toyota Motor Sales, USA
@TOYOTA
T-SB-0066-11
Rev1
June 28, 2011
Page 3 of 7
5-Speed Manual Transmission Clutch Difficult Engaging
Required Tools & Equipment
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
Crankshaft Pulley Holding Tool*
09213-54015
1
Companion Flange Holding Tool*
09330-00021
1
Clutch Diaphragm Spring Aligner**
09333-0001 3
1
Clutch Guide Tool
09301-00210
1
Pilot Bearing Puller
09303-35011
1
Pilot Bearing Installer
09304-30012
1
* Essential SST.
** Special Order.
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
REQUIRED MATERIAL
QUANTITY
Toyota Genuine Adhesive 1324, Three Bond 1324, or Equivalent
As Needed
Repair Procedure
1. Confirm the condition described in the Introduction.
Place the vehicle in every gear position (forward and reverse) and attempt to move the vehicle.
Does the vehicle move?
• YES - This bulletin does NOT apply. Continue diagnosis using the applicable Repair
Manual.
• NO -
Go to step 2.
2. Remove the manual transmission assembly to inspect the clutch disk and clutch cover.
Refer to the Technical Information System (TIS), applicable model and model year Repair
Manual:
• 2005 Tacoma :
Drivetrain - Manual Transmission!Transaxle - "Manual Transmission Unit Assy (R155) I
(R155F): Replacement"
© 2013 Toyota Motor Sales, USA
@TOYOTA
T-SB-0066-11
Rev1
June 28, 2011
Page 4 of 7
5-Speed Manual Transmission Clutch Difficult Engaging
Repair Procedure (Continued)
• 2006 - 2013 Tacoma:
Drivetrain - Manual Transmission/Transaxle - "R155/R155F Manual Transmission: Manual
Transmission Assembly: Removal"
• 2006 Tacoma: R1551 R155F
• 2007 Tacoma: R155 I R155F
• 2008 Tacoma: R155 I R155F
• 2009 Tacoma: R155/ R155F
• 2010 Tacoma: R155/R155F
• 2011 Tacoma: R155 I R155F
• 2012 Tacoma: R155 I R155F
• 2013 Tacoma: R155 I R155F
3. Does the clutch cover appear damaged, such as broken or excessively scored diaphragm
spring fingers?
• YES - This bulletin does NOT apply. Continue diagnosis using the applicable Repair
Manual.
• NO -
Go to step 4.
4. Remove the clutch cover and clutch disk assembly.
Refer to TIS, applicable model year Repair Manual:
• 2005 Tacoma:
Drivetrain - Clutch- "Clutch Unit (R155/R155F): Overhaul"
• 2006 - 2013 Tacoma:
Drivetrain - Clutch - "Clutch: Clutch Unit (for R155) I (for R155F): Removal"
• 2006 Tacoma: R155 I R155F
• 2007 Tacoma: R155/R155F
• 2008 Tacoma: R155 I R155F
• 2009 Tacoma: R155/R155F
• 2010Tacoma: R155/R155F
• 2011 Tacoma: R155 I R155F
• 2012 Tacoma: R155 I R155F
• 2013 Tacoma: R155 I R155F
© 2013 Toyota Motor Sales, USA
@TOYOTA
T-SB-0066-11
Rev1
June 28, 2011
Page 5 of 7
5-Speed Manual Transmission Clutch Difficult Engaging
Repair Procedure (Continued)
5. Inspect the clutch disk friction surface.
Figure 1. Clutch Disk Missing Friction Material
Does the clutch disk friction material display
damage such as missing or tearing of friction
material on one or both sides of the clutch disk?
See Figure 1.
• YES -
Go to step 6.
• NO - This bulletin does NOT apply.
Continue diagnosis using the applicable
Repair Manual.
6. Replace the clutch disk, clutch cover, flywheel, and clutch pedal turnover spring.
Refer to TIS, applicable model and model year Repair Manual:
• 2005 Tacoma:
• Drivetrain - Clutch- "Clutch Unit (R155/R155F): Overhaul"
• Engine/Hybrid System - Engine Mechanical- "Engine Rear Oil Seal (2TR-FE):
Replacement"
• 2006 - 2013 Tacoma:
Drivetrain - Clutch - "Clutch: Clutch Unit (for R155) I (for R155F): Installation"
• 2006 Tacoma: R155 I R155F
• 2007 Tacoma: R155 I R155F
• 2008 Tacoma: R155 I R155F
• 2009 Tacoma: R155 I R155F
• 2010 Tacoma: R155 I R155F
• 2011 Tacoma: R155 I R155F
• 2012 Tacoma: R155 I R155F
• 2013 Tacoma: R155 I R155F
© 2013 Toyota Motor Sales, USA
@TOYOTA
5-Speed
T-SB-0066-11
~anual
Rev1
June 28, 2011
Page 6 of 7
Transmission Clutch Difficult Engaging
Repair Procedure (Continued)
• 2006 - 2009 Tacoma:
Engine/Hybrid System - Engine Mechanical - "2TR-FE Engine Mechanical: Engine Rear
Oil Seal: Removal I Installation"
• 2006 Tacoma: Removal I Installation
• 2007 Tacoma: Removal I Instaflatfon
• 2008 Tacoma: Removal I Installation
• 2009 Tacoma: Removal I Installation
• 2010 - 2013 Tacoma:
Engine/Hybrid System - Engine Mechanical - "2TR-FE Engine Mechanical: Rear
Crankshaft Oil Seal: Removal I Installation"
• 201 O Tacoma: Removal I Installation
• 2011 Tacoma: Removal I Installation
• 2012 Tacoma: Removal I Installation
• 2013 Tacoma: Removal I Installation
7. Reinstall the manual transmission assembly.
Refer to TIS, applicable model year Repair Manual:
• 2005 Tacoma:
Drivetrain - Manual Transmission/Transaxle - "Manual Transmission Unit Assy (R155) I
(R155F): Replacement"
• 2006 - 2013 Tacoma:
Drivetrain - Manual Transmission/Transaxle - "R155/R155F Manual Transmission: Manual
Transmission Assembly: Installation"
• 2006 Tacoma: R155 I R155F
• 2007 Tacoma: R155 I R155F
• 2008 Tacoma: R155 I R155F
• 2009 Tacoma: R155 I R155F
• 2010 Tacoma: R155/R155F
• 2011 Tacoma: R155 I R155F
• 2012 Tacoma: R155 I R155F
• 2013 Tacoma: R155 I R155F
© 2013 Toyota Motor Sales, USA
I
@TOYOTA
T-SB-0066-11
Rev1
June 28, 2011
5-Speed Manual Transmission Clutch Difficult Engaging
Repair Procedure (Continued)
• 2005 Tacoma:
• Drivetrain - Clutch - "Clutch Pedal Sub-Assy: Replacement"
• 2006 - 2013 Tacoma:
Drivetrain - Clutch - "Clutch: Clutch Pedal: Removal I Installation"
• 2006 Tacoma: Removal I Installation
• 2007 Tacoma: Removal I Installation
• 2008 Tacoma: Removal I Installation
• 2009 Tacoma: Removal I Installation
• 2010 Tacoma: Removal I Installation
• 2011 Tacoma: Removal I Installation
• 2012 Tacoma: Removal I Installation
• 2013 Tacoma: Removal I Installation
8. Test drive the vehicle and confirm normal operation.
© 2013 Toyota Motor Sales, USA
Page 7 of 7
@TOYOTA YARIS
2014 PRE-DELIVERY SERVICE CHECK SHEET
~ I ;~
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BEFORE INSPECTION
0
01 Install DCC Fuse (see page 2) ................... ........ .......... ..
02 Install antenna* ..... ........................ .................. ...... ...... ... ..
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UNDER VEH ICLE (ON HOIST)
""'
01 Remove disc brake anti-rust covers/anti-corrosion
wheel film* ......................................................................
02 Inspect tires for defects/damage ................................. ...
03 Activate** and Initialize Tire Pressure Warning System
(TPWS) (see page 2) .............. ....... ..... ...... .. ...... ...... .. .. ... .
04 Install wheel covers/caps* ......... ........ .. ...... .............. ... ... .. .
05 Inspect for fuel , oil, coolant, and other fluid leaks ........... .
06 Inspect under the vehicle for damage, rust, etc...... ........ .
07 Visually check bolts and nuts on chassis and powertrain
for looseness ........ ................ ............................... ............ .
08 Install rubber body plugs* ..................... .. ..... .... ....... .. .. ... .
09 Install front wheel opening extension pads (see page 2)
FUNCTIONAL OPERATION
Apply parking brake and cycle "JG-ON," place gear selector in revers e, tum on
lights and rear defogger. Unlock doors; release fuel door.
01
02
03
04
05
06
07
08
Check dome, courtesy, and map lights* .... .... .. ... .... .........
Check warning/indicator lights, gauges, and horn ....... .. ..
Check windshield wipers and washers .. .. ..... ...... ....... .. ....
Check headlights, instrument lights, turn signals,
emergency flashers, and brake lights ..... ........ ...... ....... ....
Check inside/outside rear view mirror operation/
adjustment ..... ......... ... .. ........ ...... .... ... .. .... ......... .... ........ ...
Check power outlets and cigarette lighter* .. .... ... ... .. ..... ..
Check audio system and set clock ............. ···· ·········· ·- ··· ·
Install shift-lock override button cover ·· ···· ······ ······· ····· ··· ·
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Enter Odometer Reading
Reading After Test:
Reading Before Test:
01
02
03
04
05
06
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07
08
09
10
Check cold engine operation ..................................... .......
Check engine operation during warm up ................ ........ .
Check engine at normal operating temperature ........... ... .
Check clutch or automatic transm ission operation .... .... .. .
Check brake and parking brake operation ........ ......... ......
Check steering operation and off-center/vehicle
pull/flutter...... ... ........ ... ............................ ... ........ ..............
Inspect for abnormal noise and vibration ..... ..... ...............
Inspect for squeaks and rattles .... .... ..... ...... ..... .... ..... .......
Check front and rear* heater and A/C operation .. .... .. ......
Check cruise control operation*.. ....... .... .... ..... ... .. ...... ..... .
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FINAL INSPECTION AND CLEANING
01 Remove interior protective covers, unnecessary labels,
tags, etc. (Remove protective covers just before delivery
to customer) ... ............... .... .......... ..... ..... ...... .. .... .... ..... .. ....
02 Visually inspect all interior parts for installation,
damage, fit, dirt, etc. ... ... ... .. .. ....... ... .......... .... ... ...... ..... ... ..
03 Verify floor mat application and install using
retaining clips*...............................................................
04 Remove Rapgard™ and clear protective bumper film*....
05 Wash and clean vehicle ........... ...... ......... ........ .. .... ... .. .... ..
06 Inspect paint finish for scratches, chips, rust, dents,
damage, etc. ............ ............. ....... ........................... .........
07 Inspect exterior body parts for proper installation,
damage, rust, etc. ... ...... .. ...... ....... .............. ............ ........ ..
08 Place oil change sticker on inside of windshield , top
left corner ..... .... .............................. ...... .. ..... .. .. ..... ......... ...
09 Install front* license plate (see page 2) ... ..... .. ................
10 Install front bumper extension bracket** (see page 2) ...
11 Place Owner's Guide and first aid kit portfolio*
in glove box .. . .. . .. . ... .. . . .. .. . . .. ... .. . ... . . . ... . .. . . . . . . ... .. . . . .
12 Perform Techstream Health Check .. .... ... ..... .... .. ..... .. .... .
UNDER HOOD
Check engine oil and ATM* fluid levels ...........................
Check brake and clutch* fluid levels ............................ ....
Check engine coolant level .... ............... ... ... ....................
Check windshield washer fl uid level ... ....... ..... ..... ......... ..
Check battery state-of-charge using Digital Battery
System Analyzer (SOC Reading:
%) .....
06 Inspect for fuel, oil , coolant, and other fluid leaks ... ....... .
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A complete road test helps assure customer satisfaction. Drive vehicle over a
variety of road surfaces and driving conditions. Check for unusual noise and
driving performance.
Start at left front door. Check window and door lock operation (from master power
switch, if equipped). Continue around vehicle in a counterclockwise direction
checking each door and window operation, child door locks, seat belts, interior
condition, all lights, luggage compartment contents. Finish by checking headlight
aim and continue into UNDER HOOD checks.
01
02
03
04
05
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ROAD TEST
WALKAROUND INSPECTION
01 Check door and door lock operation , including each
wireless remote control/theft deterrent system* ... ... .. .. .....
02 Check window operation ...... ...................... .... .. .. .... ........ ..
03 Check that engine starts with all keys ............ ........... ...... .
04 Check that child safety door locks are in normal
(unlocked) position* ...... ...................................................
05 Check seats and seat belt operation ... ....... .... ...... ...........
06 Check rear defogger ...... ..................................................
07 Check side marker, tail, backup, cargo* and license
plate lights ...... ... ... .... ... ..... .............. .................................
08 Check luggage compartment light* and trim appearance
09 Adjust spare tire pressure, inspect for damage, and
check jack and tool installation ......... ......... .. ...... ..... .. ......
10 Check headlight aim ... .................. .... .... .... .... ...................
June 2013 Rev1
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* Inspect or install when equipped/required.
** For vehicles with VINs beginning with "VNK" only.
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Completion and retention of this from is required to comply with Toyota's Warranty Policy.
TECHNICIAN 'S SIGNATURE
SERVICE MANAGER'S SIGNATURE
NAME (PLEASE PRINT)
NAME (PLEASE PRINT)
Date
I
Dealer Name
I
Dealer Code
We hereby certify that all items
on this form have been checked
and corrected for proper
operation as required.
I
Vehicle Identification Number (Sticker)
DCC FUSE INSTALLATION
FRONT WHEEL OPENING EXTENSION PAD
To minimize battery discharge the DCC fuse (30A)
has been removed and is stored in the engine
compartment relay block. Install the DCC fuse into
the location shown.
1 Storage Location
The front wheel opening extension pad set (right and left) are loaded in
the luggage compartment at the assembly plant to avoid damage in
transit. Use this procedure for both right and left sides.
.----~~~~~~~~~~----.
1. Hook the retainers of the front
wheel opening extension pad
through the installation holes on
the fender liner.
2. Install the 2 self-tapping screws.
2 Installation Location
1 Self-tapping Screws
TPWS ACTIVATION AND INITIALIZATION
Activation Procedure**
1. Connect Techstream to DLC3 .
2. Cycle the IG switch to the "IG-ON" position and check that the Low Tire Pressure Warning Light blinks for 1 minute and then
remains illuminated.
3. Press or remove the valve core to reduce the tire inflation pressure rapidly by 6 psi (0.4 kgf/cm 2 , 40 kPA) , or more, within
30 seconds.
4. Using Techstream , check for DTCs (C2111 -C2114) . If no DTCs are stored, continue to step 5, if these DTCs are stored ,
repeat step 3.
5. Adjust all tires to the standard tire inflation pressure, as indicated on the Tire and Loading Information label inside the
driver's door jamb.
6. Check the tire pressure values of all the tires using Techstream. TPWS ECU I DATA LIST I TIREPRESS 1-4
Initialization Procedure
Refer to the Repair Manual for the Initialization proced ure .
NOTE
• If DTCs C2111-C2114 are present after repeating step 3, lift the vehicle and rotate each tire so that the tire pressure
warning valve/sensor is at the top of the wheel well. Then repeat step 3.
• To adjust the tire pressure correctly when the outside temperature is significantly colder than shop temperature,
perform a Health Check using Techstream and select the "Compensation Tire Pressure" checkbox. Compensation
pressures will be displayed on the Health Check results screen. Adjust the tire pressure when the tires are cold .
FRONT BUMPER EXTENSION BRACKET**
FRONT LICENSE PLATE INSTALLATION
For states that don't require a front license plate, the front
bumper extension mounting bracket and 2 self-tapping
screws are loaded in the luggage compartment.
For states that require a front license plate, please install per
this procedure.
Front Bumper Extension Mounting Bracket
Installation Procedure
1. Align the installation holes of the front license plate with the
dimples on the bumper.
2 . Install 2 self-tapping screws through the license plate and into
the front bumper at the dimples.
1. Clean the front bumper surface.
2. Align both holes of the front bumper extension bracket
with the dimples on the front bumper cover.
3. Install 2 self-tapping screws.
4. Remove the tape film on both sides.
1
2
3
4
Cleaning Area
Tape Film
Self-tapping Screws
Front Bumper Extension
Mounting Bracket
5 Dimples
Front License Plate Installation Procedure
NOTICE
• Do NOT pre-drill holes
into the bumper.
• Do NOT overtighten the
self-tapping screws.
1 License Plate
**For vehicles with VINs beginning with "VNK" only.
2 Self-tapping Screws