CLUTCH UNIT (for 2TR-FE) INSTALLATION


  1. INSTALL INPUT SHAFT BEARING


    1. B007PUKE01

      Using SST and a hammer, install a new input shaft bearing.

      SST
      09304-12012

    2. Install 4 new bolts.

      Torque:
      27 N*m  { 276 kgf*cm, 20 ft.*lbf }
    3. B007SKLE01

      Mark each bolt with paint as shown in the illustration.

    4. Retighten each bolt by 90°.

    5. Check that the mark on each bolt is at a 90° angle from its original position.

  2. INSTALL CLUTCH DISC ASSEMBLY


    1. B007S4EE01

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

      SST
      09301-00110

      Note

      Take care not to insert the clutch disc assembly in the wrong direction.

  3. INSTALL CLUTCH COVER ASSEMBLY


    1. B007S4XE02

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

    2. Following the procedures shown in the illustration, tighten the 6 bolts starting from the bolt located near the knock pin on the top.

      SST
      09301-00110
      Torque:
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

      Tech Tips


      • Evenly tighten the bolts by following the order shown in the illustration.

      • Tighten the bolts after checking that the disc is in the center by lightly moving the SST up and down, left and right.

  4. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY


    1. B007UYD

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

      Maximum non-alignment
      0.9 mm (0.035 in.)
    2. B007PK1E01

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

      SST
      09333-00013

  5. INSTALL CLUTCH RELEASE FORK BOOT


    1. B007RFI

      Install the clutch release fork boot.

  6. INSTALL RELEASE FORK SUPPORT


    1. B007PKOJ01

      Install the clutch release fork support to the transmission unit.

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

  7. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY


    1. B007PZB

      Apply Multemp 8158 Grease or equivalent to the release fork, the release bearing assembly, the push rod contact point and pivot points as shown in the illustration.

      Grease
      Multemp 8158 Grease or equivalent
    2. B007V88J02

      Apply clutch spline grease to the input shaft spline.

      Sealant
      Toyota Genuine Clutch Spline Grease or equivalent
    3. B007WD0E01

      Install the release bearing to the clutch release fork with the clip.

    4. Install the clutch release fork assembly to the transmission unit.

      Note

      After installation, move the fork back and forth to check that the release bearing slides smoothly.

  8. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY

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