CLUTCH UNIT INSTALLATION

INSTALL INPUT SHAFT FRONT BEARING (for 1KD-FTV, 2KD-FTV, 1GR-FE)
1. Using SST and a hammer, tap in a new bearing.
  
  SST
  
  09304-12012
  
  Tech Tips
  
  After installing the bearing to the hub, make sure that it rotates smoothly.
2. Install 2 new bolts.
  
  Torque:
  
  178 N*m { 1,815 kgf*cm, 132 ft.*lbf, for 1KD-FTV, 2KD-FTV }
  
  83 N*m { 846 kgf*cm, 61 ft.*lbf, for 1GR-FE }
INSTALL INPUT SHAFT FRONT BEARING (for 1TR-FE, 2TR-FE)
1. Using SST and a hammer, tap in a new bearing.
  
  SST
  
  09304-12012
  
  Tech Tips
  
  After installing the bearing to the hub, make sure that it rotates smoothly.
2. Install 2 new bolts.
  
  Torque:
  
  26.5 N*m { 270 kgf*cm, 20 ft.*lbf }
  
  Tech Tips
  
  The mounting bolts are tightened in 2 progressive steps.
3. Mark the mounting bolts with paint.
4. Retighten the mounting bolts by 90°in the numerical order shown in the illustration.
5. Check that the painted marks are now at a 90°angle to the position.
INSTALL CLUTCH DISC ASSEMBLY
1. Insert SST into the clutch disc. Then insert the SST (together with the clutch disc) into the flywheel.
  
  SST
  
  09301-00110
  
  Note
  
  Take care not to insert the clutch disc facing the wrong direction.
INSTALL CLUTCH COVER ASSEMBLY
1. Align the matchmarks on the clutch cover 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.
    
    Torque:
    
    19 N*m { 195 kgf*cm, 14 in.*lbf }
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.
INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
1. Using a dial indicator with roller instrument, measure the diaphragm spring tip alignment.
  
  Maximum misalignment
  
  0.5 mm (0.020 in.)
  - If the alignment is not as specified, use SST to adjust the diaphragm spring tip alignment.
  SST
  
  09333-00013
INSTALL RELEASE FORK SUPPORT
1. Install the release fork support to the manual transmission unit.
INSTALL RELEASE BEARING HUB CLIP
1. Install the release bearing hub clip to the release bearing.
INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
1. Apply Multemp 8158 Grease or equivalent to the following areas:
  - The contact surfaces of the release fork and release bearing hub.
  - The contact surfaces of the release fork and push rod.
  - The pivot points of the release fork.
    
    Grease
    
    Multemp 8158 Grease or equivalent
2. Install the release fork to the release bearing.
INSTALL CLUTCH RELEASE BEARING ASSEMBLY
1. Apply clutch spline grease to the input shaft spline.
  
  Grease
  
  Toyota Genuine Clutch Spline Grease or equivalent
2. Install the release fork (with release bearing) to the manual transmission.
  
  Note
  
  After the installation, move the fork forward and backward to check that the release bearing slides smoothly.
INSTALL CLUTCH RELEASE FORK BOOT
INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY
INSTALL FRONT PROPELLER SHAFT ASSEMBLY (4WD)
INSTALL REAR PROPELLER SHAFT ASSEMBLY
INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (4WD)

Torque:

29 N*m { 296 kgf*cm, 21 ft.*lbf }
INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY (4WD)

Torque:

29 N*m { 296 kgf*cm, 21 ft.*lbf }
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
PERFORM INITIALIZATION
1. Perform initialization Click here.
  
  Note
  
  Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
CHECK SRS WARNING LIGHT
1. Check the SRS warning light Click here.