CLUTCH UNIT(for EA66) INSTALLATION

PROCEDURE

1. INSTALL CLUTCH DISC ASSEMBLY

   1. 

      *a	Manual Transaxle Assembly Side

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

      09301-00220

      Note:

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

2. INSTALL CLUTCH COVER ASSEMBLY

   1. 

      *a

      Matchmark

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

   2. Tighten the 6 bolts uniformly in the order shown in the illustration, starting with the bolt located near the knock pin on the top.

      19.1 N*m

      195 kgf*cm

      14 ft.*lbf

      Note:

      • Following the order in the illustration, make sure to uniformly tighten the bolts 180°.

      • After checking that the clutch disc assembly is centered, gently move SST up and down, right and left to tighten the bolts.

3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

   1. 

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

      Maximum Non-alignment

      1.3 mm (0.0512 in.)

   2. 

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

      09333-00013

4. INSTALL RELEASE FORK SUPPORT

   1. w/ Precoated part

      1. Clean the release fork supprt installation hole.

      2. Install a new release fork support to the manual transaxle assembly.

         36.8 N*m

         375 kgf*cm

         27 ft.*lbf

   2. w/o Precoated part

      1. Install the release fork sipprt to the manual transaxxle assembly.

         47 N*m

         479 kgf*cm

         35 ft.*lbf

5. INSTALL CLUTCH RELEASE FORK BOOT

   1. Install the clutch release fork boot to the manual transaxle assembly.

6. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

   1. 

      	Clutch Spline Grease or equivalent
      	Release Hub Grease or equivalent

      Apply release hub grease to the clutch release fork sub-assembly and clutch release bearing assembly contact, clutch release fork sub-assembly and push rod contact, and clutch release fork sub-assembly pivot points.

      Sealant

      Toyota Genuine Release Hub Grease or equivalent

   2. Apply clutch spline grease to the spline coupling part.

      Sealant

      Toyota Genuine Clutch Spline Grease or equivalent

7. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

   1. Install the clutch release bearing assembly to the clutch release fork sub-assembly with the release bearing hub clip, and then install them to the manual transaxle assembly.

8. INSTALL MANUAL TRANSAXLE ASSEMBLY

   Click hereClick here