Installation

CLUTCH: CLUTCH UNIT: INSTALLATION

1. INSTALL RELEASE FORK SUPPORT

(a) Install the release fork support spring to the release fork support.





(b) Install the release fork support to the manual transmission unit assembly with the 2 bolts.

Torque : 26 Nm (265 kgf-cm, 19 ft-lbf)

2. INSTALL CLUTCH RELEASE HUB BALL BEARING

(a) Install the thrust cone spring, thrust cone spring plate washer and clutch release hub ball bearing to the clutch release hub as shown in the illustration.





(b) Using a snap ring expander, install the snap ring.

3. INSTALL CLUTCH RELEASE BEARING HUB

(a) Fill the groove inside the release bearing hub with grease.





(b) Apply grease to the contact surface between the release hub bearing and the clutch cover.

NOTICE:
* Be sure to apply an even and thin layer of grease.
* Excessive grease or a lump of grease on the contact surface between the release hub bearing and the clutch cover can splatter and result in trouble.

(c) Using SST, secure the clutch release hub ball bearing.





SST : 09950-60020

09951-00810

09726-05021

(d) Install the clutch cover assembly, release bearing plate washer and release bearing wave washer.

(e) Using a snap ring expander, install the snap ring.





4. INSTALL CLUTCH COVER ASSEMBLY

(a) Apply clutch spline grease to the input shaft spline.

Sealant:

Toyota Genuine Clutch Spline Grease or equivalent

(b) Install the clutch cover assembly to the input shaft.

5. INSTALL CLUTCH DISC ASSEMBLY

(a) Install the clutch disc assembly to the transmission unit.





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

6. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

(a) Install the pin and wave washer to the clutch release fork with a new E-ring.





(b) Apply release hub grease to the contact surface between, the release fork and release bearing hub, the contact surface between the release fork and push rod, and release fork pivot points as shown in the illustration.





Sealant:

Toyota Genuine Release Hub Grease or equivalent

(c) Install the clutch release fork sub-assembly to the release fork support.

NOTICE:
* Do not use excess force to install the clutch release fork sub-assembly.
* After installation, move the fork back and forth to check that the clutch release bearing hub slides smoothly.

7. INSTALL MANUAL TRANSMISSION ASSEMBLY

Installation