Clutch Unit Installation

Using SST and a hammer, tap in the bearing.

SST

09304-12012

HINT:

After installing the bearing to the hub, make sure that it rotates smoothly.

Install 2 new bolts.

Torque:

178 N*m{1815 kgf*cm, 132 ft.*lbf} for KD series

83 N*m{847 kgf*cm, 61 ft.*lbf} for 1GR-FE

Insert SST into the clutch disc. Then insert SST (together with the clutch disc) into the flywheel.

SST

09301-00110

NOTICE:

Make sure not to insert the clutch disc facing the wrong direction.

Align the matchmarks on the clutch cover and flywheel.

Loosely install the 6 bolts.

Tighten the 6 bolts as described below.

1. Determine the first bolt to be tightened by choosing the bolt closest to the knock pin.
   

2. Uniformly tighten the 6 bolts in diametrically opposite pairs relative to the position of the first bolt. Use the illustration as a reference.
   

   Torque:

   19 N*m{195 kgf*cm, 14 ft.*lbf}

Lightly move SST up and down, and right and left.

SST

09301-00110

Check that the disc is in the center, and then tighten the bolts.

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

Maximum misalignment:

0.5 mm (0.020 in.)

1. If the misalignment is greater than the maximum, use SST to adjust the diaphragm spring tip alignment.
   

SST

09333-00013

Install the release fork support to the manual transmission unit.

Torque:

49 N*m{500 kgf*cm, 36 ft.*lbf} for KD series

47 N*m{479 kgf*cm, 35 ft.*lbf} for 1GR-FE

Install the release bearing hub clip to the release bearing.

Apply Multemp 8158 Grease or equivalent to the following areas:

1. The contact surfaces of the release fork and release bearing hub.
   
2. The contact surfaces of the release fork and push rod.
   
3. The pivot points of the release fork.
   

   Grease:

   Multemp 8158 Grease or equivalent
   

Install the release fork to the release bearing.

Apply clutch spline grease to the input shaft spline.

Grease:

Toyota Genuine Clutch Spline Grease or equivalent

Install the release fork (with release bearing) to the manual transmission.

NOTICE:

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

Install the manual transmission.
For the R150/R151 manual transmission, refer to the following procedures (Toyota Fortuner RM0000011B0004X.html).
For the R150F/R151F manual transmission, refer to the following procedures (Toyota Fortuner RM0000011AJ003X.html).