Installation
CLUTCH: CLUTCH UNIT: INSTALLATION
INSTALLATION
1. INSTALL CLUTCH DISC ASSEMBLY
(a) Insert SST into the clutch disc assembly, then insert them both into the flywheel sub-assembly.
SST: 09301-00110
NOTICE: Insert clutch disc assembly in the correct direction.
2. INSTALL CLUTCH COVER ASSEMBLY
(a) Align the matchmark on the clutch cover assembly with that on the flywheel sub-assembly.
(b) Following the procedures shown in the illustration, tighten the 6 bolts in order, starting with the bolt located near the knock pin at the top.
Torque: 19 Nm (195 kgf-cm, 14 ft-lbf)
HINT:
- 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 disc is in the center, and tighten the bolts.
SST: 09301-00110
3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
(a) Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.
Maximum non-alignment:
0.5 mm (0.020 in.)
(b) If the alignment is not as specified, using SST, adjust the diaphragm spring tip alignment.
SST: 09333-00013
4. INSTALL RELEASE FORK SUPPORT
(a) Install the release fork support onto the transaxle assembly.
Torque: 37 Nm (375 kgf-cm, 27 ft-lbf)
5. INSTALL CLUTCH RELEASE FORK BOOT
6. INSTALL RELEASE BEARING HUB CLIP
7. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
(a) Apply release hub grease to the contact surfaces of the release fork and release bearing assembly, release fork and push rod, and release fork and fork support.
Sealant:
Toyota Genuine Release Hub Grease or equivalent
(b) Install the release fork onto the release bearing assembly.
8. INSTALL CLUTCH RELEASE BEARING ASSEMBLY
(a) Apply clutch spline grease to the input shaft spline.
Sealant:
Toyota Genuine Clutch Spline Grease or equivalent
(b) Install the clutch release bearing with release fork onto the transaxle assembly.
NOTICE: After the installation, move the fork forward and backward to check that the release bearing slides smoothly.
9. INSTALL MANUAL TRANSAXLE ASSEMBLY
Installation