CLUTCH UNIT(for Diesel) INSTALLATION

PROCEDURE


  1. INSTALL CLUTCH DISC ASSEMBLY


    1. A01CW6PC02
      *a Transaxle side

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

      SST
      09301-00310

      Note

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

  2. INSTALL CLUTCH COVER ASSEMBLY


    1. A01CYCYC01
      *a Matchmark

      Align the matchmarks on the clutch cover assembly 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  { 194 kgf*cm, 14 ft.*lbf }

      Note


      • Following the order in the illustration, make sure to uniformly tighten the bolts 180°.

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

  3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY


    1. A01CXN1
      A01CXI1N02

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

      Maximum misalignment
      1.3 mm (0.0512 in.)

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

      SST
      09333-00013

  4. INSTALL RELEASE FORK SUPPORT


    1. A01CWP4

      w/ Precoated part


      1. Clean the release fork support installation hole.

      2. Install a new release fork support to the manual transaxle assembly.

        Torque:
        36.8 N*m  { 375 kgf*cm, 27 ft.*lbf }

    2. w/o Precoated part


      1. 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. A01CW1B

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

  6. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY


    1. A01CX9OC01
      A01CX8N Multemp 8158 grease or equivalent

      Apply Multemp 8158 grease or equivalent to the following areas:


      • The surfaces on the clutch release fork sub-assembly that contact the clutch release bearing.


      • The surfaces on the clutch release fork sub-assembly that contact the push rod of the clutch release fork support.


      • The surfaces on the clutch release fork sub-assembly that contact the clutch release fork support.

      Grease
      Multemp 8158 grease or equivalent

    2. Install the clutch release fork sub-assembly to the clutch release bearing.

  7. INSTALL CLUTCH RELEASE BEARING ASSEMBLY


    1. A01CYV4C01
      A01CX8N Toyota Genuine Clutch Spline Grease or equivalent

      Apply clutch spline grease to the input shaft spline.

      Grease
      Toyota Genuine Clutch Spline Grease or equivalent
    2. A01CWK8

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

      Note

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

  8. INSTALL MANUAL TRANSAXLE ASSEMBLY

    for EA64:

    Click here

    for EA64F:

    Click here