CLUTCH UNIT (for C551) INSTALLATION


  1. INSTALL CLUTCH DISC ASSEMBLY


    1. A0136R3E04

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

      Text in Illustration
      A0137RP Flywheel Side
      SST
      09301-00131

      Note

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

  2. INSTALL CLUTCH COVER ASSEMBLY


    1. A0137J5E02
      Text in Illustration
      *a Temporarily
      *b Matchmark

      Align the matchmark on the clutch cover assembly and the flywheel sub-assembly.

    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.

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

      Tech Tips

      Move SST up and down, right and left gently after checking that the clutch disc assembly is in the center and tighten the bolts.

      SST
      09301-00131

  3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY


    1. A01378S

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

      Maximum non-alignment
      0.5 mm (0.0197 in.)
    2. A0138QME02

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

      SST
      09333-00013

  4. INSTALL NO. 1 CLUTCH HOUSING COVER


    1. Install the No. 1 clutch housing cover to the transaxle case.

  5. INSTALL CLUTCH RELEASE FORK LEVER SHAFT OIL SEAL


    1. A0138FCE01

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

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

  6. INSTALL CLUTCH RELEASE FORK LEVER


    1. A01385M

      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 lever and the spline coupling part.

      Text in Illustration
      A0137RP Release hub grease
      Grease
      Toyota Genuine Release Hub Grease or equivalent

      Note

      Remove any grease extending beyond the clutch release fork lever joining part.

    2. Install the clutch release fork lever to the transaxle case together with the release fork torsion spring, release fork torsion spring stopper and the clutch release fork.

    3. A013754

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

    4. A01387TE01

      Secure the release fork torsion spring to the clutch release fork.

      Note

      Hold the release fork torsion spring and the release fork torsion spring stopper up to the upper end of the clutch release fork lever first, and then secure the release fork torsion spring.

  7. INSTALL CLUTCH RELEASE BEARING ASSEMBLY


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

    2. A01375U

      Apply clutch spline grease to the input shaft spline.

      Text in Illustration
      A0137RP Clutch spline grease
      Grease
      Toyota Genuine Clutch Spline Grease or equivalent

  8. INSTALL RELEASE FORK RETRACTING SPRING HANGER


    1. Install the release fork retracting spring hanger to the clutch release fork lever with the bolt.

      Torque:
      33 N*m  { 336 kgf*cm, 24 ft.*lbf }

  9. INSTALL MANUAL TRANSAXLE ASSEMBLY

    Click here