Installation

CLUTCH: CLUTCH UNIT (for C59): INSTALLATION

1. INSTALL CLUTCH DISC ASSEMBLY

(a) Insert SST into the clutch disc assembly, 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) Align the matchmark on the clutch cover assembly with the one on the flywheel sub-assembly.





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

Torque : 19 Nm (195 kgf-cm, 14 ft-lbf)

HINT
* Following the order in the illustration, tighten the bolts evenly one at a time.
* Move SST up and down, right and left lightly after checking that the disc is in the center, and tighten the bolts.
SST : 09301-00110

3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

(a) Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.





Maximum non-alignment:

0.9 mm (0.0354 in.)

(b) If the alignment is not as specified, adjust the diaphragm spring tip alignment using SST.

SST : 09333-00013

4. INSTALL RELEASE FORK SUPPORT

(a) Install the release fork support onto the transaxle assembly.





Torque : 37 Nm (375 kgf-cm, 27 ft-lbf)

5. INSTALL CLUTCH RELEASE FORK BOOT

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





6. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

(a) Apply release hub grease to the contact surfaces between the release fork and release bearing assembly, release fork and push rod, and release fork and fork support.





Grease:

Toyota Genuine Release Hub Grease or equivalent

(b) Install the release fork onto the release bearing assembly with the clip.

7. 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 with the release fork onto the transaxle assembly.

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

8. INSTALL MANUAL TRANSAXLE ASSEMBLY

Installation.