CLUTCH UNIT(for 2WW) INSTALLATION

PROCEDURE

  1. INSTALL CLUTCH DISC ASSEMBLY

    1. C199344C02

      *a

      Transaxle side

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

      09301-00310

      Note:

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

  2. INSTALL CLUTCH COVER ASSEMBLY

    1. C299402C03

      *a

      Matchmark

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

    2. Install and 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 N*m

      194 kgf*cm

      14 ft.*lbf

      Note:

      • Be sure to uniformly tighten the bolts 180° at a time according to the order in the illustration.

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

  3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

    1. C299403N01

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

      09333-00013

      Maximum misalignment

      1.3 mm (0.0512 in.)

      If the misalignment is more than the maximum, using SST, adjust the diaphragm spring tip alignment.

  4. INSTALL RELEASE FORK SUPPORT

    1. C304173

      Install the release fork support to the manual transaxle assembly.

      47 N*m

      479 kgf*cm

      35 ft.*lbf

  5. INSTALL CLUTCH RELEASE FORK BOOT

    1. C299398

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

  6. INSTALL CLUTCH RELEASE FORK SUPPORT BOOT

    1. C299405

      Install the clutch release fork support boot and a new snap ring to the clutch release fork sub assembly.

  7. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

    1. C299404C02
      V100135

      Release hub grease

      Apply release hub grease to the clutch release fork sub-assembly where it contacts the clutch release bearing assembly, push rod and release fork support.

      Grease

      Toyota Genuine Release Hub Grease or equivalent

    2. Install the release fork to the clutch release bearing assembly with the release bearing hub clip.

  8. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    1. C202870C02
      V100135

      Clutch spline grease

      Apply clutch spline grease to the input shaft spline.

      Grease

      Toyota Genuine Clutch Spline Grease or equivalent

    2. C344789C01
      V100135

      Release hub grease

      Apply release hub grease to the inside of the clutch release bearing.

      Grease

      Toyota Genuine Release Hub Grease or equivalent

    3. C299395

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

      Note:

      After the installation, move the fork forward and backward to check that the release bearing slides smoothly.

  9. INSTALL MANUAL TRANSAXLE ASSEMBLY

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