INSTALL INPUT SHAFT FRONT BEARING
Using SST and a hammer, tap in a new bearing.
After installing the bearing to the hub, make sure that it rotates smoothly.
Install 2 new bolts.
INSTALL CLUTCH DISC ASSEMBLY
Insert SST into the clutch disc. Then insert the SST (together with the clutch disc) into the flywheel.
Take care not to insert the clutch disc facing the wrong direction.
INSTALL CLUTCH COVER ASSEMBLY
Align the matchmarks on the clutch cover and flywheel.
Tighten the 6 bolts as described below.
Determine the first bolt to be tightened by choosing the bolt closest to the knock pin.
Uniformly tighten the 6 bolts in diametrically opposite pairs relative to the position of the first bolt. Use the illustration as a reference.
Lightly move SST up and down, and right and left.
Check that the disc is in the center, and then tighten the bolts.
INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
Using a dial indicator with roller instrument, measure the diaphragm spring tip alignment.
|0.9 mm (0.035 in.)|
If the alignment is as specified, use SST to adjust the diaphragm spring tip alignment.
INSTALL RELEASE FORK SUPPORT
Install the release fork support to the manual transmission unit.
INSTALL RELEASE BEARING HUB CLIP
Install the release bearing hub clip to the release bearing.
INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
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.
|Multemp 8158 Grease or equivalent|
Install the release fork to the release bearing.
INSTALL CLUTCH RELEASE BEARING ASSEMBLY
Apply clutch spline grease to the input shaft spline.
|Toyota Genuine Clutch Spline Grease or equivalent|
Install the release fork (with release bearing) to the manual transmission.
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 the front propeller shaft Click here.
INSTALL REAR PROPELLER SHAFT ASSEMBLY
Install the rear propeller shaft Click here.
INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (4WD)
INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY (4WD)
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Perform initialization Click here.
Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.