CLUTCH UNIT INSTALLATION


  1. INSTALL INPUT SHAFT BEARING


    1. A01KEPVE04

      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, install sure that it rotates smoothly.

    2. Install 2 new bolts.

      Torque:
      5L
      122.5 N*m  { 1250 kgf*cm, 90 ft.*lbf }
      2KD-FTV
      178 N*m  { 1815 kgf*cm, 131 ft.*lbf }

  2. INSTALL CLUTCH DISC ASSEMBLY


    1. A01KGUAE01
      Text in Illustration
      *A 5L
      *B 2KD-FTV
      A01KFFI Engine side

      Insert SST in the clutch disc, then insert them in the flywheel.

      SST
      09301-00110

      Note

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

  3. INSTALL CLUTCH COVER ASSEMBLY


    1. A01KHCHE03
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the clutch cover and the flywheel.

    2. Following the procedures shown in the illustration, tighten the 6 bolts, in the order starting the bolt locating near the knock pin on the top.

      Torque:
      19.1 N*m  { 195 kgf*cm, 14 ft.*lbf }

      Tech Tips


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

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

      SST
      09301-00110

  4. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY


    1. A01KFV9

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

      Maximum non-alignment
      0.5 mm (0.020 in.)
    2. A01KEMGE02

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

      SST
      09333-00013

  5. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY


    1. Apply release hub grease to the release fork and hub contact, release fork and push rod contact and release fork pivot points.

      Sealant
      Toyota Genuine Release Hub Grease or equivalent

    2. Install the release fork to the hub bearing.

  6. INSTALL CLUTCH RELEASE FORK BOOT

  7. INSTALL CLUTCH RELEASE BEARING ASSEMBLY


    1. Apply the clutch spline grease to the input shaft spline.

      Sealant
      Toyota Genuine Clutch Spline Grease or equivalent

    2. Install the bearing to the release fork, and then install them to the transmission assembly.

      Note

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

  8. INSTALL MANUAL TRANSMISSION ASSEMBLY