Clutch Unit: Installation

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 1: Installing Release Fork Support

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 the illustration.
2. Using a snap ring expander, install the snap ring.
   Fig 2: Installing Clutch Release Hub Ball Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.
   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.
     Fig 3: Locating Grease Application Area Between Release Hub Bearing And Clutch Cover

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, secure the clutch release hub ball bearing.

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

4. Install the clutch cover assembly, release bearing plate washer and release bearing wave washer.
   Fig 4: Securing Clutch Release Hub Ball Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a snap ring expander, install the snap ring.

1. Apply clutch spline grease to the input shaft spline.

   Sealant: 

   Toyota Genuine Clutch Spline Grease or equivalent 

2. Install the clutch cover assembly to the input shaft.
   Fig 5: Installing Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the clutch disc assembly to the transmission unit.
   NOTE: Take care not to insert the clutch disc assembly in the wrong direction.
   Fig 6: Installing Clutch Disc Assembly To Transmission Unit

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the pin and wave washer to the clutch release fork with a new E-ring.
   Fig 7: 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 the illustration.

   Sealant: 

   Toyota Genuine Release Hub Grease or equivalent 

   Fig 8: Identifying Grease Application Area

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.

(See INSTALLATION )