Clutch Unit: Installation

Fig 1: Checking Flywheel Subassembly Runout

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1. INSTALL RELEASE FORK SUPPORT 
   1. Install the release fork support spring to the release fork support.
   2. Install the release fork support to the manual transmission unit assembly with the 2 bolts.

   Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) 

   Fig 2: Installing Release Fork Support To Manual Transmission Unit Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. INSTALL CLUTCH RELEASE HUB BALL BEARING 
   1. Install the thrust cone spring, thrust cone spring plate washer and clutch release hub ball bearing to the clutch release hub as shown in Fig 3 .
   2. Using a snap ring expander, install the snap ring.
   Fig 3: Installing Snap Ring

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3. INSTALL CLUTCH RELEASE BEARING HUB 
   1. Fill the groove inside the release bearing hub with grease.
   2. Apply grease to the contact surface between the release hub bearing and the clutch cover.
      Fig 4: Identifying Grease Application Area Between Release Hub Bearing & Clutch Cover

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      • 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.
   3. Using SST, secure the clutch release hub ball bearing.
      Fig 5: Securing Clutch Release Hub Ball Bearing

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09950-60020 (09951-00810, 09726-05021) 

   4. Install the clutch cover assembly, release bearing plate washer and release bearing wave washer.
   5. Using a snap ring expander, install the snap ring.
   Fig 6: Installing Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. INSTALL CLUTCH COVER ASSEMBLY 
   1. Apply clutch spline grease to the input shaft spline.

      Sealant: 

      Part No. 08887-01706, CLUTCH SPLINE GREASE or equivalent 

   2. Install the clutch cover assembly to the input shaft.
5. INSTALL CLUTCH DISC ASSEMBLY 
   1. Install the clutch disc assembly to the transmission unit.
   Fig 7: Installing Clutch Disc Assembly To Transmission Unit

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   NOTE: Take care not to insert the clutch disc assembly in the wrong direction.
6. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY 
   1. Install the pin and wave washer to the clutch release fork with a new E-ring.
      Fig 8: Installing Pin And Wave Washer To Clutch Release Fork With New E-Ring

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. 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 Fig 9 .
      Fig 9: Identifying Grease Application Area

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Sealant: 

      Part No. 08887-01806, RELEASE HUB GREASE or equivalent 

   3. Install the clutch release fork sub-assembly to the release fork support.
   NOTE:

   • 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 

(See Step 6 in INSTALLATION )