Installation

CLUTCH UNIT:

COMPONENTS






INSTALLATION

1. INSTALL CLUTCH DISC ASSEMBLY





(a) Insert SST in the clutch disc assembly, then insert them in the flywheel sub-assembly.
SST: 09301-00210

NOTE: Take care not to insert clutch disc assembly in the wrong direction.

2. INSTALL CLUTCH COVER ASSEMBLY





(a) Align the matchmarks on the clutch cover assembly and flywheel sub-assembly.
(b) Following the procedures shown in the illustration, tighten the 6 bolts, in the order starting the bolt locating near the knock pin on the top.
Torque: 19 Nm (195 kgf-cm, 14 ft-lbf)

HINT:
- Following the order in the illustration, tighten the bolts at a time evenly.
- Move SST up and down, right and left lightly, after checking that the disc is in the center, tighten the bolts.

3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY





(a) Using a dial indicator with roller instrument, check the diaphragm spring tip alignment.
Maximum non-alignment:
0.5 mm (0.020 in.)
If 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 to the transaxle assembly.
Torque: 37 Nm (375 kgf-cm, 27 ft-lbf)
5. INSTALL RELEASE BEARING HUB CLIP
6. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY





(a) Apply release hub grease to the release fork and release bearing assembly contact, release fork and push rod contact and release fork pivot points.
Grease:
Toyota Genuine Release Hub Grease or equivalent
7. INSTALL CLUTCH RELEASE BEARING ASSEMBLY
(a) Apply the clutch spline grease to the input shaft spline.
Grease:
Toyota Genuine Clutch Spline Grease or equivalent
(b) Install the bearing to the release fork, and then install them to the transaxle assembly.

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

8. INSTALL CLUTCH RELEASE FORK BOOT
9. INSTALL MANUAL TRANSAXLE ASSEMBLY (Installation)