CLUTCH UNIT(for Diesel) INSTALLATION

PROCEDURE

  1. INSTALL CLUTCH DISC ASSEMBLY

    1. C116730C02

      *a

      Transaxle side

      Insert SST into the clutch disc assembly, and then insert them into the flywheel.

      09301-00310

      Note:

      Do not insert the clutch disc assembly in the wrong direction.

  2. INSTALL CLUTCH COVER ASSEMBLY

    1. C116732C01

      *a

      Matchmark

      Align the matchmarks on the clutch cover assembly with the one on the flywheel.

    2. Tighten the 6 bolts uniformly in the order shown in the illustration, starting with the bolt located near the knock pin on the top.

      19 N*m

      194 kgf*cm

      14 ft.*lbf

      Note:

      • Following the order in the illustration, make sure to uniformly tighten the bolts 180°.

      • After checking that the disc is in the center, gently move SST up and down, and right and left to tighten the bolts.

  3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

    1. C116192N02
      C116193

      Using a dial indicator with a roller instrument, measure the diaphragm spring tip alignment.

      Maximum misalignment

      1.3 mm (0.0512 in.)

      If the alignment is not as specified, using SST, adjust the diaphragm spring tip alignment.

      09333-00013

  4. INSTALL RELEASE FORK SUPPORT

    1. C304173

      Install the release fork support to the manual transaxle assembly.

      47 N*m

      479 kgf*cm

      35 ft.*lbf

  5. INSTALL CLUTCH RELEASE FORK BOOT

    1. C113599

      Install the clutch release fork boot onto the manual transaxle assembly.

  6. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

    1. C133433C01
      V100135

      Multemp 8158 grease or equivalent

      Apply Multemp 8158 grease or equivalent to the following areas:

      • The surfaces on the clutch release fork sub-assembly that contact the clutch release bearing.

      • The surfaces on the clutch release fork sub-assembly that contact the push rod of the clutch release fork support.

      • The surfaces on the clutch release fork sub-assembly that contact the clutch release fork support.

      Grease

      Multemp 8158 grease or equivalent

    2. Install the clutch release fork sub-assembly to the clutch release bearing.

  7. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    1. C133434C01
      V100135

      Toyota Genuine Clutch Spline Grease or equivalent

      Apply clutch spline grease to the input shaft spline.

      Grease

      Toyota Genuine Clutch Spline Grease or equivalent

    2. C113576

      Install the clutch release bearing with clutch release fork sub-assembly to the manual transaxle assembly.

      Note:

      After the installation, move the fork forward and backward to check that the release bearing slides smoothly.

  8. INSTALL MANUAL TRANSAXLE ASSEMBLY

    for EA64:

    Click here

    for EA64F:

    Click here