CLUTCH UNIT(for C551) INSTALLATION

PROCEDURE


  1. INSTALL CLUTCH DISC ASSEMBLY


    1. A01VFSKE05
      Text in Illustration
      *1 Clutch Disc Assembly
      *a Flywheel side

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

      SST
      09301-00131

      Note

      Insert clutch disc assembly in the correct direction.

  2. INSTALL CLUTCH COVER ASSEMBLY


    1. A01VGYLE02
      Text in Illustration
      *a Matchmark
      *b Temporarily

      Align the matchmark on the clutch cover assembly with that on the flywheel sub-assembly.

    2. Following the procedures shown in the illustration, tighten the 6 bolts in order, starting with the bolt located near the knock pin at the top.

      SST
      09301-00131
      Torque:
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

      Tech Tips


      • Following the order in the illustration, tighten the bolts evenly one at a time.

      • Move SST up and down, right and left lightly after checking that the disc is in the center, and tighten the bolts.

  3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY


    1. A01VJSK

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

      Maximum non-alignment
      0.5 mm (0.0197 in.)
    2. A01VGFFE04

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

      SST
      09333-00013

  4. INSTALL CLUTCH RELEASE FORK SHAFT OIL SEAL


    1. A01VFJ3E01

      Using SST and a hammer, tap in a new clutch release fork shaft oil seal until its surface is flush with the transaxle case.

      SST
      09950-60010   ( 09951-00290 )
      09950-70010   ( 09951-07150 )

  5. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY


    1. A01VEUV

      Apply release hub grease to the contact surface between the clutch release bearing assembly and the clutch release fork, the rotating and sliding parts of the clutch release fork shaft and the spline coupling part.

      Text in Illustration
      A01VL3H Release hub grease

      Note

      Apply grease uniformly to the rotating and sliding parts of the clutch release fork shaft and the spline coupling part. Remove any grease extending beyond the clutch release fork shaft joining part.

    2. Install the clutch release fork sub-assembly to the transaxle case together with the clutch release fork.

    3. A01VH7M

      Using a screwdriver and hammer, install a new E-ring.

  6. INSTALL CLUTCH RELEASE BEARING ASSEMBLY


    1. Engage the release bearing hub clip and install the clutch release bearing assembly to the clutch release fork.

    2. A01VI0K

      Apply clutch spline grease to the input shaft spline.

      Text in Illustration
      A01VL3H Clutch spline grease
      Grease
      Toyota Genuine Clutch Spline Grease or equivalent

  7. INSTALL NO. 1 CLUTCH HOUSING COVER


    1. Install the No. 1 clutch housing cover to the manual transaxle assembly.

  8. INSTALL MANUAL TRANSAXLE ASSEMBLY

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