CLUTCH  CLUTCH UNIT(for C50)  INSTALLATION  


PROCEDURE

Hide 31250 1.INSTALL CLUTCH DISC ASSEMBLY

a.
C296283
1.573,4.188 2.094,4.188 false 2.25,1.885 2.667,2.427 2.667,2.427 1.958,3.333 false 2.146,4.104 2.573,4.354 0.427,0.25 10 false *1 0.74,3.365 1.146,3.677 0.406,0.313 10 false *a 2.708,2.354 3.135,2.604 0.427,0.25 10 false SST
*1 Clutch Disc Assembly
*a Flywheel Sub-assembly Side


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

SST
09301-00210  

NOTICE:

Insert the clutch disc assembly in the correct direction.



Hide 31210 2.INSTALL CLUTCH COVER ASSEMBLY

a.
C303399
0.927,1.604 0.646,1.531 0.646,1.531 0.99,1.531 false 2.01,1.177 2.615,1.646 2.615,1.646 2.75,1.646 false 2.458,0.073 3.125,0.427 0.667,0.354 10 false 1 (*a) ,4 0.875,0.063 1.083,0.302 0.208,0.24 10 false 7 0.354,0.99 0.563,1.229 0.208,0.24 10 false 3 0.448,1.438 0.76,1.635 0.313,0.198 10 false *b 0.854,1.938 1.01,2.177 0.156,0.24 10 false 6 2.365,1.958 2.771,2.167 0.406,0.208 10 false 2, 5 2.938,1.052 3.146,1.292 0.208,0.24 10 false 8 2.792,1.583 3.25,1.781 0.458,0.198 10 false SST
*a Temporarily Install
*b Matchmark


Align the matchmark on the clutch cover assembly with that 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.

SST
09301-00210  

Torque:
19.1 N*m (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 clutch disc assembly is in the center, and tighten the bolts.




Hide 31210 3.INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

a.
C303400

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

Maximum Non-alignment:

0.5 mm (0.0197 in.)



b.
C303401
1.979,1.26 2.375,0.708 2.375,0.708 2.521,0.708 false 2.594,0.635 3.052,0.833 0.458,0.198 10 false SST

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

SST
09333-00013  


Hide 31236B 4.INSTALL RELEASE FORK SUPPORT

a.

Install the release fork support to the manual transaxle assembly.

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


Hide 31126 5.INSTALL CLUTCH RELEASE FORK BOOT

a.

Install the clutch release fork boot to the manual transaxle assembly.


Hide 31232A 6.INSTALL RELEASE BEARING HUB CLIP

a.

Install the release bearing hub clip to the clutch release bearing assembly.


Hide 31204 7.INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

a.
C264543
0,0 0,0 false
V100135

Release Hub Grease


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 release cylinder push rod, and clutch release fork sub-assembly and release fork support.

Grease:

Toyota Genuine Release Hub Grease or equivalent



b.

Install the clutch release fork sub-assembly with the clutch release bearing assembly to the manual transaxle assembly.


Hide 31230 8.INSTALL CLUTCH RELEASE BEARING ASSEMBLY

a.
C296284
1.573,0.854 1.927,1.177 0.354,0.323 10 false A
V100135

Clutch Spline Grease


Apply clutch spline grease to the input shaft splines.

NOTICE:

Do not apply grease to portion (A) shown in the illustration.


Grease:

Toyota Genuine Clutch Spline Grease or equivalent



b.

Install the clutch release bearing assembly with the clutch release fork sub-assembly to the manual transaxle assembly.

NOTICE:

After the installation, move the clutch release fork sub-assembly forward and backward to check that the clutch release bearing assembly slides smoothly.