CLUTCH UNIT (for C59): Installation

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: Installing Clutch Disc Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the matchmark on the clutch cover assembly with the one on the flywheel sub-assembly.
2. Following the order shown in the illustration, tighten the 6 bolts, 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 the illustration, tighten the bolts evenly one turn at a time.
   • Lightly move SST up and down, and right and left after checking that the disc is centered, and tighten the bolts.
     Fig 2: Tightening Clutch Cover Assembly Bolts

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09301-00110 

1. Using a dial indicator with a roller tip, check the diaphragm spring tip alignment.

   Maximum misalignment: 

   0.9 mm (0.0354 in.) 

2. If the alignment is not as specified, adjust the diaphragm spring tip alignment using SST.

   SST 09333-00013 

   Fig 3: Checking Diaphragm Spring Tip Alignment

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the release fork support to the transaxle assembly.

   Torque: 37 N*m (375 kgf*cm, 27 ft.*lbf) 

   Fig 4: Locating Release Fork Support

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the clutch release fork boot to the manual transaxle.
   Fig 5: Identifying Clutch Release Fork Boot

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 as shown in the illustration.

   Grease: 

   Toyota Genuine Release Hub Grease or equivalent 

2. Install the release fork to the release bearing assembly with the clip.
   Fig 6: Locating Grease Applying Area Of Release Fork And Release Bearing Assembly, Release Fork And Push Rod

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Grease: 

   Toyota Genuine Clutch Spline Grease or equivalent 

   NOTE: Do not apply grease to portion A shown in the illustration.
   Fig 7: Locating Grease Applying Area Of Input Shaft Spline

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the clutch release bearing with the release fork onto the transaxle assembly.
   NOTE: After installation, move the fork back and forth to check that the release bearing slides smoothly.

(See INSTALLATION ).