CLUTCH UNIT(for RC60, RC61) INSTALLATION

PROCEDURE


  1. INSTALL CLUTCH DISC ASSEMBLY

    B003PHXC02
    *a Flywheel Side

    1. Insert SST into the clutch disc assembly. Then insert SST (together with the clutch disc) into the flywheel.

      SST
      09301-00110

      Note

      Be sure to install the clutch disc so that it is facing in the correct direction.

  2. INSTALL CLUTCH COVER ASSEMBLY


    1. B003K7JC01
      *a Matchmark

      Align the matchmarks on the clutch cover assembly and flywheel.

    2. Tighten the 6 bolts as described below.


      1. Determine the first bolt to be tightened by choosing the bolt closest to the knock pin.

      2. Uniformly tighten the 6 bolts in diametrically opposite pairs relative to the position of the first bolt. Use the illustration as a reference.

    3. Lightly move SST up and down, and right and left.

      SST
      09301-00110

    4. Check that the disc is in the center, and then tighten the bolts.

      Torque:
      19.1 N*m  { 195 kgf*cm, 14 ft.*lbf }

  3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY


    1. B003LH4

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

      Maximum misalignment
      0.5 mm (0.020 in.)

      • B003JWON01

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

      SST
      09333-00013

  4. INSTALL RELEASE FORK SUPPORT


    1. Install the release fork support to the manual transmission unit.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  5. INSTALL CLUTCH RELEASE FORK DUST SEAL


    1. Install the clutch release fork dust seal to the clutch release fork sub-assembly.

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

  6. INSTALL CLUTCH RELEASE BEARING ASSEMBLY


    1. B003RWHC01
      B003R2S Multemp 8158 grease or equivalent

      Apply grease to the clutch release bearing assembly.

      Grease
      Multemp 8158 grease or equivalent
      Amount of Grease
      0.3 to 0.5 g (0.011 to 0.018 oz)

      Tech Tips

      When replacing the clutch release bearing assembly with a new one, do not apply grease.

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

    3. B003RSHC01
      *a The surfaces of the release fork that contact the release bearing
      *b The surfaces of the release fork that contact the release fork support
      *c The surfaces of the release fork that contact the push rod of the release cylinder
      B003R2S Multemp 8158 grease or equivalent

      Apply grease or equivalent to the following areas.

      Grease
      Multemp 8158 grease or equivalent
      Amount of Grease
      The surfaces of the release fork that contact the release bearing 1.0 to 1.3 g (0.04 to 0.05 oz)
      The surfaces of the release fork that contact the release fork support 1.3 to 1.8 g (0.05 to 0.06 oz)
      The surfaces of the release fork that contact the push rod of the release cylinder 0.5 to 0.9 g (0.02 to 0.03 oz)

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

    5. Install the clutch release bearing assembly together with the clutch release fork sub-assembly to the clutch housing.

      Note

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

    6. B003PFCC01
      *a Contact surface of the bearing
      B003R2S Toyota Genuine Clutch Spline Grease or equivalent

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

      Grease
      Toyota Genuine Clutch Spline Grease or equivalent

      Note

      Make sure that no grease adheres to the contact surface of the bearing.

  7. INSTALL CLUTCH RELEASE FORK BOOT

  8. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY

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