T-SB-0385-09 November 23, 2009

6-Speed Manual Transmission Clutch Difficult Engaging

Service
Category Drivetrain

Section Clutch Market USA

Applicability

YEAR(S) MODEL(S) ADDITIONAL INFORMATION

2007 – 2010 FJ Cruiser Drive Type(s): 4WD

Engine(s): 1GR
Transmission(s): 6MT
VDS(s): BU11F, BU4BF

2005 – 2010 Tacoma Drive Type(s): 4WD, 2WD

Engine(s): 1GR
Transmission(s): 6MT
VDS(s): LU42N, LU4EN, TU22N, TU4CN, TU4GN,
TU62N, UU42N, UU4EN

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

PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY

31250-60370
31250-04100 Disc Assembly, Clutch 1
31250-04080
31210-60240
31210-60280
31210-04100 Cover Assembly, Clutch 1
31210-04090
31210-04091

© 2009 Toyota Motor Sales, USA Page 1 of 6

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6-Speed Manual Transmission Clutch Difficult Engaging

Warranty Information

OP CODE DESCRIPTION MODEL VDS TIME OFP T1 T2

FJ Cruiser – 3.5
TU22N
Tacoma X-Runner 2.7
TU4CN
TU62N
311021 R & R Clutch Disk Tacoma PreRunner 2.8
TU4GN
31250-####0 72 12
LU42N
LU4EN
Tacoma 4WD 3.1
UU42N
UU4EN
Radial Ball Bearing – –
Combo B 0.1
(for Clutch Release)

APPLICABLE WARRANTY
• This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 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

SPECIAL SERVICE TOOLS (SST’S) PART NUMBER QTY

Clutch Guide Tool 09301-00220 1

Clutch Diaphragm Spring Aligner* 09333-00013 1

* Special Order

NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.

REQUIRED MATERIAL QTY

High Temperature Grease As Needed

© 2009 Toyota Motor Sales, USA

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6-Speed Manual Transmission Clutch Difficult Engaging

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 off 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:
• 2007 / 2008 / 2009 / 2010 FJ Cruiser:
Drivetrain – Manual Transmission/Transaxle – “RA61F Manual Transmission: Manual
Transmission Assembly: Removal”
• 2005 Tacoma:
Drivetrain – Manual Transmission/Transaxle – “Manual Transmission Unit Assy (RA60) /
(RA60f) Replacement”
• 2006 Tacoma:
Drivetrain – Manual Transmission/Transaxle – “RA60 / RA60f Manual Transmission:
Manual Transmission Assembly: Removal”
• 2007 Tacoma:
Drivetrain – Manual Transmission/Transaxle – “RA60 / RA60f Manual Transmission:
Manual Transmission Assembly: Removal”
• 2008 Tacoma:
Drivetrain – Manual Transmission/Transaxle – “RA60 / RA60f Manual Transmission:
Manual Transmission Assembly: Removal”
• 2009 Tacoma:
Drivetrain – Manual Transmission/Transaxle – “RA60 / RA60f Manual Transmission:
Manual Transmission Assembly: Removal”

© 2009 Toyota Motor Sales, USA

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6-Speed Manual Transmission Clutch Difficult Engaging

Repair Procedure (Continued)

• 2010 Tacoma:
Drivetrain – Manual Transmission/Transaxle – “RA60 / RA60f Manual Transmission:
Manual Transmission Assembly: Removal”
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:
• 2007 / 2008 / 2009 / 2010 FJ Cruiser:
Drivetrain – Clutch – “Clutch: Clutch Unit: Removal”
• 2005 Tacoma:
Drivetrain – Clutch – “Clutch Unit (Ra60/ra60f): Overhaul”
• 2006 Tacoma:
Drivetrain – Clutch – “Clutch: Clutch Unit (for RA60) / (for RA60f): Removal”
• 2007 Tacoma:
Drivetrain – Clutch – “Clutch: Clutch Unit (for RA60) / (for RA60f): Removal”
• 2008 Tacoma:
Drivetrain – Clutch – “Clutch: Clutch Unit (for RA60) / (for RA60f): Removal”
• 2009 Tacoma:
Drivetrain – Clutch – “Clutch: Clutch Unit (for RA60) / (for RA60f): Removal”
• 2010 Tacoma:
Drivetrain – Clutch – “Clutch: Clutch Unit (for RA60) / (for RA60f): Removal”
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.

© 2009 Toyota Motor Sales, USA

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6-Speed Manual Transmission Clutch Difficult Engaging

Repair Procedure (Continued)

7. Inspect the clutch disk for separation of the center Figure 1..
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:
• 2007 / 2008 / 2009 / 2010 FJ Cruiser:
Drivetrain – Clutch – “Clutch: Clutch Unit: Installation”
• 2005 Tacoma:
Drivetrain – Clutch – “Clutch Unit (Ra60/ra60f): Overhaul”
• 2006 Tacoma:
Drivetrain – Clutch – “Clutch: Clutch Unit (for RA60) / (for RA60f): Installation”
• 2007 Tacoma:
Drivetrain – Clutch – “Clutch: Clutch Unit (for RA60) / (for RA60f): Installation”
• 2008 Tacoma:
Drivetrain – Clutch – “Clutch: Clutch Unit (for RA60) / (for RA60f): Installation”
• 2009 Tacoma:
Drivetrain – Clutch – “Clutch: Clutch Unit (for RA60) / (for RA60f): Installation”
• 2010 Tacoma:
Drivetrain – Clutch – “Clutch: Clutch Unit (for RA60) / (for RA60f): Installation”

© 2009 Toyota Motor Sales, USA

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6-Speed Manual Transmission Clutch Difficult Engaging

Repair Procedure (Continued)

9. Reinstall the manual transmission assembly.

Refer to TIS, applicable model and model year Repair Manual:
• 2007 / 2008 / 2009 / 2010 FJ Cruiser:
Drivetrain – Manual Transmission/Transaxle – “RA61F Manual Transmission: Manual
Transmission Assembly: Installation”
• 2005 Tacoma:
Drivetrain – Manual Transmission/Transaxle – “Manual Transmission Unit Assy (RA60) /
(RA60f) Replacement”
• 2006 Tacoma:
Drivetrain – Manual Transmission/Transaxle – “RA60 / RA60f Manual Transmission:
Manual Transmission Assembly: Installation”
• 2007 Tacoma:
Drivetrain – Manual Transmission/Transaxle – “RA60 / RA60f Manual Transmission:
Manual Transmission Assembly: Installation”
• 2008 Tacoma:
Drivetrain – Manual Transmission/Transaxle – “RA60 / RA60f Manual Transmission:
Manual Transmission Assembly: Installation”
• 2009 Tacoma:
Drivetrain – Manual Transmission/Transaxle – “RA60 / RA60f Manual Transmission:
Manual Transmission Assembly: Installation”
• 2010 Tacoma:
Drivetrain – Manual Transmission/Transaxle – “RA60 / RA60f Manual Transmission:
Manual Transmission Assembly: Installation”
10. Test drive vehicle and confirm normal operation.

© 2009 Toyota Motor Sales, USA