Clutch Unit: Installation

INSTALL CLUTCH DISC ASSEMBLY
1. 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.
  
  Fig 1: Identifying Clutch Disc Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH COVER ASSEMBLY
1. Align the matchmarks on the clutch cover and flywheel.
2. 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 N*m (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.
      
      Fig 2: Identifying Bolts
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
1. 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
INSTALL RELEASE FORK SUPPORT
1. Install the release fork support to the transaxle.
  Torque: 47 N*m (480 kgf*cm, 35 ft.*lbf)
  
  Fig 3: Identifying Release Fork Support To Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
1. 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
2. Install the release fork to the release bearing.
3. Install the release bearing hub clip.
  
  Fig 4: Identifying Clutch Release Fork Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH RELEASE BEARING ASSEMBLY
1. Apply clutch spline grease to the input shaft spline as shown in the illustration.
  Sealant: Toyota Genuine Clutch Spline Grease, or equivalent
2. 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.
  
  Fig 5: Identifying Clutch Spline Grease To Input Shaft Spline
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH RELEASE FORK BOOT
INSTALL MANUAL TRANSAXLE ASSEMBLY
1. Install the transaxle ( INSTALLATION ).