GSIC - Global Service Information Center

# CLUTCH UNIT > INSTALLATION

## for Preparation Click here

1. INSTALL INPUT SHAFT FRONT BEARING

1. Using SST and a hammer, tap in a new bearing.

   SST
     09304-12012

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

1. Install 2 new bolts.

   Torque:
     178 N*m{ 1815 kgf*cm , 132 ft.*lbf } for 1KD-FTV, 2KD-FTV
     27 N*m{ 270 kgf*cm , 20 ft.*lbf } for 1TR-FE, 2TR-FE
     26.5 N*m{ 270 kgf*cm , 20 ft.*lbf } for 1GR-FE

2. INSTALL CLUTCH DISC ASSEMBLY

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

   SST
     09301-00110

   NOTICE:
     Take care not to insert the clutch disc facing the wrong direction.

3. INSTALL CLUTCH COVER ASSEMBLY

1. Align the matchmarks on the clutch cover and flywheel.

1. 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 in.*lbf }

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

   SST
     09301-00110

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

4. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

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

   Maximum misalignment:
     0.5 mm (0.020 in.)

   1. If the alignment is not as specified, use SST to adjust the diaphragm spring tip alignment.
   SST
     09333-00013

5. INSTALL RELEASE FORK SUPPORT

1. Install the release fork support to the manual transmission unit.

6. INSTALL RELEASE BEARING HUB CLIP

1. Install the release bearing hub clip to the release bearing.

7. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

1. Apply release hub grease 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.

      Release hub grease:
        Part No. 08887-01806 GREASE or equivalent

1. Install the release fork to the release bearing.

8. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

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

   Clutch spline grease:
     Part No. 08887-01706 or equivalent

1. 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.

9. INSTALL CLUTCH RELEASE FORK BOOT

10. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY

11. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (4WD)

12. INSTALL REAR PROPELLER SHAFT ASSEMBLY

13. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (4WD)

Torque:
  29 N*m{ 296 kgf*cm , 21 ft.*lbf }

14. INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY (4WD)

Torque:
  29 N*m{ 296 kgf*cm , 21 ft.*lbf }

15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

16. PERFORM INITIALIZATION

1. Perform initialization (Click here ).

   NOTICE:
     Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

17. CHECK SRS WARNING LIGHT

1. Check the SRS warning light (Click here).