CLUTCH UNIT (for C553) INSTALLATION


  1. INSTALL CLUTCH DISC ASSEMBLY


    1. A0136R3E02
      Text in Illustration
      *a Flywheel Side

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

      SST
      09301-00131

      Note

      Do not insert the clutch disc 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 with the one on the flywheel.

    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

      After checking that the disc is in the center, gently move SST up and down, right and left to tighten the bolts.

      SST
      09301-00131

  3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

    A01378S

    1. 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 onto the transaxle case.

  5. INSTALL CLUTCH RELEASE FORK LEVER SHAFT OIL SEAL

    A0138FCE01

    1. Using SST and a hammer, tap in a new select lever shaft oil seal until its surface is flush with the manual 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 release bearing and the release fork, the rotating and sliding parts of the release lever and the spline coupling part.

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

      Note

      Apply grease uniformly to the rotating and sliding parts of the release lever and spline coupling part. Remove any grease extending beyond the release lever joining part.

    2. A01379J

      Install the release fork lever onto the transaxle case together with the torsion spring, spring stopper and the release fork.

    3. A013754

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

    4. A01387T

      Secure the torsion spring to the release fork.

      Note

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

  7. INSTALL CLUTCH RELEASE BEARING ASSEMBLY


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

      Grease
      Toyota Genuine Clutch Spline Grease or equivalent

    2. Install the release bearing onto the transaxle case.

  8. INSTALL RELEASE FORK RETRACTING SPRING HANGER


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

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

  9. INSTALL MANUAL TRANSAXLE ASSEMBLY

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