Clutch Unit: Installation

WARNING: This page is about a different car, the 2008 Toyota Yaris. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL CLUTCH DISC ASSEMBLY
1. Insert SST into the clutch disc assembly, then insert them both into the flywheel sub-assembly.
  SST 09301-00110
  
  NOTE: Insert the clutch disc assembly in the correct direction.
  
  Fig 1: Identifying Special Tool
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH COVER ASSEMBLY
1. Align the matchmark on the clutch cover assembly with that on the flywheel sub-assembly.
2. Following the procedures shown in Fig 2, tighten the 6 bolts in order, starting with the bolt located near the knock pin at the top.
  Torque: 19 N.m (195 kgf*cm, 14 ft.*lbf)
  
  HINT:
  - Following the order in Fig 2, tighten the blots 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
  
  Fig 2: Aligning Matchmark On Clutch Cover Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
1. Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.
  Maximum non-alignment: 0.5 mm (0.020 in.)
  
  Fig 3: Checking Diaphragm Spring Tip Alignment
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. If the alignment is not as specified, using SST, adjust the diaphragm spring tip alignment.
  SST 09333-00013
  
  Fig 4: Identifying Special Tool
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RELEASE FORK SUPPORT
1. Install the release fork support onto the transaxle assembly.
  Torque: 37 N.m (375 kgf*cm, 27 ft.*lbf)
INSTALL CLUTCH RELEASE FORK BOOT
INSTALL RELEASE BEARING HUB CLIP
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 fork support.
  Sealant:
  
  Toyota Genuine Release Hub Grease or Equivalent
2. Install the release fork onto the release bearing assembly.
  
  Fig 5: 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.
  Sealant:
  
  Toyota Genuine Clutch Spline Grease or Equivalent
  
  NOTE: Do not apply grease to portion A shown in Fig 6 .
2. Install the clutch release bearing with release fork onto the transaxle assembly.
  NOTE: After the installation, move the fork forward and backward to check that the release bearing slides smoothly.
  
  Fig 6: Locating Clutch Spline
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSAXLE ASSEMBLY (See INSTALLATION )