CLUTCH UNIT(for 1WW) INSTALLATION

PROCEDURE


  1. INSTALL CLUTCH DISC ASSEMBLY


    1. A002MOIE02

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

      SST
      09301-00310

      Note

      Insert the clutch disc with the disc facing in the correct direction.

  2. INSTALL CLUTCH COVER ASSEMBLY


    1. A002OPSE02
      Text in Illustration
      *a Matchmark

      Align the matchmark on the clutch cover with the one on the flywheel.

    2. Install and 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 }

      Note


      • Be sure to uniformly tighten the bolts 180° at a time according to the order in the illustration.

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

  3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY


    1. A002M01E01

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

      Maximum misalignment
      1.3 mm (0.0512 in.)

      If the misalignment is more than the maximum, using SST, adjust the diaphragm spring tip alignment.

      SST
      09333-00013

  4. INSTALL RELEASE FORK SUPPORT


    1. A002MLT

      Install the release fork support to the manual transaxle assembly.

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

  5. INSTALL CLUTCH RELEASE FORK BOOT


    1. A002QQB

      Install the clutch release fork boot to the manual transaxle assembly.

  6. INSTALL CLUTCH RELEASE FORK SUPPORT BOOT


    1. A002NHV

      Install the clutch release fork support boot and a new snap ring to the clutch release fork sub-assembly.

  7. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

    A002OCV

    1. Apply release hub grease to the clutch release fork sub-assembly where it contacts the clutch release bearing assembly, push rod and release fork support.

      Grease
      Toyota Genuine Release Hub Grease or equivalent
      Text in Illustration
      A002OPC Release hub grease

    2. Install the release fork to the clutch release bearing assembly with the release bearing hub clip.

  8. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    A002P1L

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

      Grease
      Toyota Genuine Clutch Spline Grease or equivalent
      Text in Illustration
      A002OPC Clutch spline grease
    2. A002ODE

      Apply release hub grease to the inside of the clutch release bearing.

      Grease
      Toyota Genuine Release Hub Grease or equivalent
      Text in Illustration
      A002OPC Release hub grease
    3. A002LL9

      Install the clutch release bearing together with the release fork to the manual transaxle assembly.

      Note

      After the installation, move the fork forward and backward to check that the release bearing slides smoothly.

  9. INSTALL MANUAL TRANSAXLE ASSEMBLY


    1. Install the manual transaxle assembly Click here.