CLUTCH UNIT (for C551A) INSTALLATION


  1. INSTALL CLUTCH DISC ASSEMBLY


    1. A0136PJE01

      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. A0138TK

      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. A0137AA

      Apply release hub grease to the clutch release fork, clutch release fork lever and the clutch release fork lever bushings.

      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 and the clutch release fork to the transaxle case.

    3. Install a new E-ring to the clutch release fork lever.

  7. INSTALL CLUTCH RELEASE BEARING ASSEMBLY


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

    2. A0136NQ

      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 SHIFT STROKE SENSOR


    1. Apply MP grease to a new O-ring, and install it to the shift stroke sensor.

    2. A01373GE02
      Text in Illustration
      *a Sensor Arm (Actuator Side)
      *b Sensor Arm (Sensor Side)

      Set the shift stroke sensor so that the sensor side and the actuator side sensor arms are in the positions shown in the illustration.

    3. Turn the shift stroke sensor clockwise and fix it with the 2 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

  9. INSTALL MULTI-MODE MANUAL TRANSAXLE ASSEMBLY

    Click here