CLUTCH UNIT(for R151) INSTALLATION

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PROCEDURE

1. *a Flywheel side
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   INSTALL CLUTCH DISC ASSEMBLY

   
   

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

      09301-00110

      Note:

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

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   INSTALL CLUTCH COVER ASSEMBLY

   
   
   1. 

      *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.

      09301-00110

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

      19.1 N*m

      195 kgf*cm

      14 ft.*lbf

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   INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

   
   
   1. 

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

      Maximum misalignment
      0.5 mm (0.020 in.)

      
      
      • 

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

      09333-00013

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   INSTALL RELEASE FORK SUPPORT

   
   

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

      49 N*m

      500 kgf*cm

      36 ft.*lbf

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   INSTALL CLUTCH RELEASE FORK SUPPORT BOOT (for 5L-E and TR Engine)

   
   

   1. Install the clutch release fork support boot to the clutch release fork sub-assembly.

   2. Install the release fork support spring to the clutch release fork sub-assembly.

6. Click here

   INSTALL CLUTCH RELEASE FORK DUST SEAL (for GD and KD Engine)

   
   

   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.

7. Click here

   INSTALL CLUTCH RELEASE BEARING ASSEMBLY

   
   
   1. 

      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)

      Tip:

      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. 

      *A	for 5L-E and TR Engine
      *B	for GD and KD Engine
      *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
      	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. 

      *A	for 5L-E and TR Engine
      *B	for GD and KD Engine
      *a	Contact surface of the bearing
      	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.

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   INSTALL CLUTCH RELEASE FORK BOOT

9. Click here

   INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY

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