Installation

CLUTCH: CLUTCH UNIT: INSTALLATION

INSTALLATION





1. INSTALL CLUTCH DISC ASSEMBLY
(a) Insert SST in the clutch, and then insert them in the flywheel.
SST: 09301-00220
NOTE: Take care not to insert the clutch disc in the wrong direction.





2. INSTALL CLUTCH COVER ASSEMBLY
(a) Align the matchmarks on the clutch cover and flywheel.
(b) Install and tighten the 6 bolts as described below.
(1) Determine the first bolt to be tightened by choosing the bolt closest to the knock pin.
(2) Uniformly tighten the 6 bolts relative to the position of the first bolt to be tightened. Use the illustration as a reference.
Torque: 19 Nm (195 kgf-cm, 14 ft-lbf)
HINT:
- Evenly tighten the bolts by following the order shown in the illustration.
- Tighten the bolts after checking that the disc is in the center by lightly moving the SST up and down, left and right.





3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
(a) Using a dial indicator with a roller instrument, measure the diaphragm spring tip alignment.
Maximum non-alignment:
0.5 mm (0.020 in.)
If the alignment is greater than the maximum, adjust the diaphragm spring tip alignment using SST.
SST: 09333-00013
4. INSTALL RELEASE FORK SUPPORT
(a) Install the release fork support to the transaxle.
Torque: 47 Nm (480 kgf-cm, 35 ft-lbf)






5. 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 support.
Sealant:
Toyota Genuine Release Hub Grease, or equivalent
(b) Install the release fork to the release bearing.
(c) Install the release bearing hub clip.






6. INSTALL CLUTCH RELEASE BEARING ASSEMBLY
(a) Apply clutch spline grease to the input shaft spline as shown in the illustration.
Sealant:
Toyota Genuine Clutch Spline Grease, or equivalent
(b) Install the release fork with the release bearing assembly to the manual transaxle.
NOTE: After installation, move the fork back and forth to check that the release bearing slides smoothly.

7. INSTALL CLUTCH RELEASE FORK BOOT
8. INSTALL MANUAL TRANSAXLE ASSEMBLY
(a) Install the transaxle Installation.