CLUTCH UNIT(for C550) INSTALLATION

PROCEDURE

  1. INSTALL CLUTCH DISC ASSEMBLY

    1. F100378C01
      V100135

      Flywheel Sub-assembly Side

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

      09301-00131

      Note:

      Do not insert the clutch disc assembly in the wrong direction.

  2. INSTALL CLUTCH COVER ASSEMBLY

    1. C304478C01

      *a

      Temporarily

      *b

      Matchmark

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

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

      09301-00131

      19.1 N*m

      195 kgf*cm

      14 ft.*lbf

      Tip:

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

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

  3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

    1. C304479

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

      Maximum Non-alignment

      0.5 mm (0.0197 in.)

    2. C304480N01

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

      09333-00013

  4. INSTALL NO. 1 CLUTCH HOUSING COVER

    1. Install the No. 1 clutch housing cover to the manual transaxle assembly.

  5. INSTALL CLUTCH RELEASE FORK LEVER SHAFT OIL SEAL

    1. F100377N01

      Using SST and a hammer, tap in a new clutch release fork lever shaft oil seal until its surface is flush with the manual transaxle assembly.

      09950-60010

      09951-00290

      09950-70010

      09951-07150

  6. INSTALL CLUTCH RELEASE FORK LEVER

    1. C306146C01
      V100135

      Release Hub Grease

      Apply release hub grease to the contact surfaces of the clutch release bearing assembly and the clutch release fork, the rotating and sliding parts of the clutch release fork lever, and the spline coupling.

      Grease

      Toyota Genuine Release Hub Grease or equivalent

      Note:

      Wipe off any grease extending beyond the contact surfaces of the clutch release fork lever.

    2. Install the clutch release bearing assembly to the clutch release fork.

    3. Install the clutch release fork with clutch release bearing assembly to the manual transaxle assembly together with the clutch release fork lever.

    4. Install the clip to the clutch release bearing assembly.

    5. F100370

      Using a screwdriver and a hammer, install a new E-ring.

  7. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

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

    2. C306148C01
      V100135

      Clutch Spline Grease

      Apply clutch spline grease to the input shaft spline.

      Grease

      Toyota Genuine Clutch Spline Grease or equivalent

  8. INSTALL MANUAL TRANSAXLE ASSEMBLY

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