CLUTCH UNIT INSTALLATION

PROCEDURE


  1. INSTALL CLUTCH DISC ASSEMBLY


    1. A004HSDE01
      Text in Illustration
      *1 Clutch Disc Assembly
      *2 Flywheel Sub-assembly

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

      SST
      09301-00110

      Note

      Insert the clutch disc assembly in the correct direction.

  2. INSTALL CLUTCH COVER ASSEMBLY


    1. Reuse the flywheel sub-assembly and clutch cover assembly:


      1. A004HWKE01
        Text in Illustration
        *a Matchmark

        Align the matchmark on the clutch cover assembly with that on the flywheel sub-assembly.

    2. Replace the flywheel sub-assembly or clutch cover assembly:


      1. A004K9KE01
        Text in Illustration
        *a Unbalance Mark

        Position the clutch cover assembly so that there is a gap of at least 120° between the unbalance marks on the flywheel sub-assembly and the clutch cover assembly.

    3. A004J7YE01

      Following the procedures shown in the illustration, tighten the 6 bolts in order, starting with the bolt located near the knock pin at the top.

      SST
      09301-00110
      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Tech Tips


      • Following the order in the illustration, tighten the bolts evenly one at a time.

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

  3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY


    1. A004JSW

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

      Maximum non-alignment
      0.5 mm (0.0197 in.)
    2. A004KU8E01

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

      SST
      09333-00013

  4. INSTALL RELEASE FORK SUPPORT


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

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

  5. INSTALL CLUTCH RELEASE FORK BOOT


    1. Install the clutch release fork boot to the manual transmission assembly.

  6. INSTALL RELEASE BEARING HUB CLIP


    1. Install the 3 release bearing hub clips to the clutch release bearing assembly.

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

  7. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY


    1. A004JHA

      Apply release hub grease to the contact surfaces of the clutch release fork sub-assembly and clutch release bearing assembly, clutch release fork sub-assembly and clutch release cylinder push rod, and clutch release fork sub-assembly and release fork support.

      Text in Illustration
      A004I9S Release Hub Grease
      Grease
      Toyota Genuine Release Hub Grease or equivalent
    2. A004HGW

      Apply release hub grease to the clutch release bearing assembly as shown in the illustration.

      Text in Illustration
      A004HD0 Release Hub Grease
      Grease
      Toyota Genuine Release Hub Grease or equivalent

    3. Engage the 2 release bearing hub clips and install the clutch release fork sub-assembly to the clutch release bearing assembly.

  8. INSTALL CLUTCH RELEASE BEARING ASSEMBLY


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

      Note

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

    2. A004HXRE03

      Apply clutch spline grease to the input shaft spline.

      Text in Illustration
      A004I9S Clutch Spline Grease
      Grease
      Toyota Genuine Clutch Spline Grease or equivalent

      Note

      Do not apply grease to portion A shown in the illustration.

  9. INSTALL MANUAL TRANSMISSION ASSEMBLY

    Click here