Installation

CLUTCH: CLUTCH UNIT: INSTALLATION; 2013 MY FR-S [03/2012 -]

1. INSTALL CLUTCH DISC ASSEMBLY

(a) Insert SST into the clutch disc assembly, and then insert them both into the flywheel sub-assembly.









SST : 09301-00110

NOTICE:
Insert the clutch disc assembly in the correct direction.

2. INSTALL CLUTCH COVER ASSEMBLY

(a) Reuse the flywheel sub-assembly and clutch cover assembly:

(1) Align the matchmark on the clutch cover assembly with that on the flywheel subassembly.









(b) Replace the flywheel sub-assembly or clutch cover assembly:

(1) Position the clutch cover assembly so that there is a gap of at least 120° between the unbalance marks on the flywheel sub-assembly and the clutch cover assembly.









(c) Following the procedures shown in the illustration, tighten the 6 bolts in order, starting with the bolt located near the knock pin at the top.





SST : 09301-00110

Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)

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

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 (0.0197 in.)

(b) If the 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 manual transmission assembly.

Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)

5. INSTALL CLUTCH RELEASE FORK BOOT

(a) Install the clutch release fork boot to the manual transmission assembly.

6. INSTALL RELEASE BEARING HUB CLIP

(a) Install the 3 release bearing hub clips to the clutch release bearing assembly.

(b) Install the release bearing hub clip to the clutch release fork sub-assembly.

7. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

(a) Apply release hub grease to the contact surfaces of the clutch release fork sub-assembly and clutch release bearing assembly, clutch release fork sub-assembly and clutch release cylinder push rod, and clutch release fork sub-assembly and release fork support.









Grease:

Toyota Genuine Release Hub Grease or equivalent

(b) Engage the 2 release bearing hub clips and install the clutch release fork sub-assembly to the clutch release bearing assembly.

8. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

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









Grease:

Toyota Genuine Clutch Spline Grease or equivalent

NOTICE:
Do not apply grease to portion A shown in the illustration.

(b) Install the clutch release bearing assembly with the clutch release fork sub-assembly to the manual transmission assembly.

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

9. INSTALL MANUAL TRANSMISSION ASSEMBLY

Installation