CLUTCH UNIT (for 5L-E) INSTALLATION


  1. INSTALL INPUT SHAFT FRONT BEARING


    1. A01DVKOE01

      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:
      123 N*m  { 1,250 kgf*cm, 90 ft.*lbf }
  2. INSTALL CLUTCH DISC ASSEMBLY

    A01DX10E02

    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.

  3. INSTALL CLUTCH COVER ASSEMBLY


    1. A01E0WKE01

      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.

  4. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY


    1. A01E183E01

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

      Maximum misalignment
      0.9 mm (0.035 in.)

      • A01DXUQE01

        If the alignment is as specified, use SST to adjust the diaphragm spring tip alignment.

      SST
      09333-00013
  5. INSTALL RELEASE FORK SUPPORT


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

  6. INSTALL RELEASE BEARING HUB CLIP


    1. Install the release bearing hub clip to the release bearing.

  7. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY


    1. A01DWQ9

      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.

  8. INSTALL CLUTCH RELEASE BEARING ASSEMBLY


    1. A01DX9IE01

      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.

  9. INSTALL CLUTCH RELEASE FORK BOOT

  10. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY


    1. Install the manual transmission unit.

      G58 manual transmission Click here.

      G58F manual transmission Click here.

  11. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (4WD)


    1. Install the front propeller shaft Click here.

  12. INSTALL REAR PROPELLER SHAFT ASSEMBLY


    1. Install the rear propeller shaft Click here.

  13. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (4WD)

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

    Torque:
    29 N*m  { 296 kgf*cm, 21 ft.*lbf }
  15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  16. 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.