CLUTCH UNIT (for 1KD-FTV) INSTALLATION


  1. INSTALL INPUT SHAFT BEARING


    1. A01KG0YE01

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

      SST
      09304-12012

      Tech Tips

      After installing the input shaft bearing in the hub, make sure that it rotates smoothly.

    2. Install the 2 bolts.

      Torque:
      178 N*m  { 1815 kgf*cm, 131 ft.*lbf }

  2. INSTALL CLUTCH DISC ASSEMBLY


    1. A01KFHCE02

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

      Text in Illustration
      A01KFFI Flywheel Side
      SST
      09301-00110

      Note

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

  3. INSTALL CLUTCH COVER ASSEMBLY


    1. A01KHCHE04
      Text in Illustration
      *a Matchmark
      *b Temporarily

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

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

      Torque:
      19 N*m  { 195 kgf*cm, 14 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
      09301-00110

  4. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY


    1. A01KFV9E01

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

      Maximum non-alignment
      1.3 mm (0.051 in.)
    2. A01KEMGE02

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

      SST
      09333-00013

  5. INSTALL RELEASE FORK SUPPORT


    1. A01KGLAE02

      Install the release fork support to the transmission unit.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

  6. INSTALL CLUTCH RELEASE FORK BOOT


    1. A01KEBTE01

      Install the clutch release fork boot to the transmission unit.

  7. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY


    1. A01KHGO

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

      Text in Illustration
      A01KFFI Release Hub Grease
      Sealant
      Toyota Genuine Release Hub Grease or equivalent
    2. A01KGB8E01

      Apply clutch spline grease to the input shaft spline.

      Text in Illustration
      A01KFFI Clutch Spline Grease
      Sealant
      Toyota Genuine Clutch Spline Grease or equivalent
    3. A01KGZBE02
      Text in Illustration
      *1 Clutch Release Fork
      *2 Clutch Release Bearing
      *3 Clip

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

    4. Install the clutch release fork with the clutch release bearing to the transmission unit.

      Note

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

  8. INSTALL MANUAL TRANSMISSION ASSEMBLY