CLUTCH UNIT INSTALLATION


  1. INSTALL INPUT SHAFT BEARING


    1. A01CJAIE01

      Using SST and a hammer, install a new input shaft bearing.

      SST
      09304-12012

      Tech Tips

      After assembling the input shaft bearing to the hub, make sure that it rotates smoothly.

  2. INSTALL CLUTCH DISC ASSEMBLY


    1. A01CH3DE01

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

      SST
      09301-00120

      Note

      Take care not to insert the clutch disc assembly in the wrong direction.

  3. INSTALL CLUTCH COVER ASSEMBLY


    1. A01CIYVE01

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

    2. In the order shown in the illustration, tighten the 10 bolts starting from the bolt located near the knock pin on the top.

      Torque:
      43 N*m  { 440 kgf*cm, 32 ft.*lbf }

      Tech Tips


      • Evenly tighten the bolts by following the order shown in the illustration.

      • Tighten the bolts after checking that the disc is in the center by lightly moving SST up and down, left and right.

      SST
      09301-00120

  4. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY


    1. A01CJA7E01

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

      Maximum misalignment
      0.5 mm (0.020 in.)

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

      SST
      09333-00013

  5. INSTALL CLUTCH RELEASE FORK BOOT


    1. Install the clutch release fork boot.

  6. INSTALL RELEASE FORK SUPPORT


    1. A01CHMM

      Install the clutch release fork support to the transmission unit.

      Torque:
      47 N*m  { 480 kgf*cm, 35 ft.*lbf }

  7. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY


    1. A01CIBRE01

      Apply release hub grease to the release fork, the release bearing assembly, the push rod contact point and the pivot points as shown in the illustration.

      Grease
      Toyota Genuine Release Hub Grease or equivalent
    2. A01CIZAE01

      Apply clutch spline grease to the input shaft spline.

      Grease
      Toyota Genuine Clutch Spline Grease or equivalent
    3. A01CIT1

      Install the release bearing to the clutch release fork with the clip.

    4. A01CJ29

      Install the clutch release fork assembly to the transmission unit.

      Note

      After installation, move the fork back and forth to check that the release bearing slides smoothly.

  8. INSTALL MANUAL TRANSMISSION ASSEMBLY

    Click here.