CLUTCH UNIT (for 1KD-FTV) INSTALLATION


  1. INSTALL INPUT SHAFT BEARING


    1. A003EOLE01

      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, make sure that it rotates smoothly.

    2. Install the 2 bolts.

      Torque:
      178 N*m  { 1,815 kgf*cm, 131 ft.*lbf }

  2. INSTALL CLUTCH DISC ASSEMBLY


    1. A003DDKE01

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

      SST
      09301-00110

      Note

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

  3. INSTALL CLUTCH COVER ASSEMBLY


    1. A003H0AE02

      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.

      SST
      09301-00110
      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 the SST up and down, left and right.

  4. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY


    1. A003G6I

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

      Maximum non-alignment
      1.3 mm (0.051 in.)
    2. A003CZWE01

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

      SST
      09333-00013

  5. INSTALL CLUTCH RELEASE FORK BOOT


    1. A003GLN

      Install the clutch release fork boot.

  6. INSTALL RELEASE FORK SUPPORT


    1. A003CA3J01

      Install the clutch release fork support to the transmission unit.

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

  7. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY


    1. A003HVL

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

      Sealant
      Toyota Genuine Release Hub Grease or equivalent
    2. A003CG0J02

      Apply clutch spline grease to the input shaft spline.

      Sealant
      Toyota Genuine Clutch Spline Grease or equivalent
    3. A003B2AE01

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

    4. Install the clutch release fork assembly to the transmission unit.

      Note

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

  8. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY

    Click here