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Type :
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Specification :
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Outer diameter 250MM
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Pulley :
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Brand :
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NUOJIN
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Number :
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CKT-065
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Quality :
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NEW
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Delivery time :
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30DAYS
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The installation of Toyota manual transmission clutch kit (pressure plate, friction disc, release bearing) must follow the process of "Cleaning → Centering → Diagonal Uniform Torquing → Lubrication → Bleeding → Commissioning". The key lies in accurate centering, proper torque application, and thorough hydraulic system bleeding to avoid slipping, incomplete disengagement, or abnormal noise.
Park the vehicle on a flat surface, engage the parking brake, and place wheel chocks front and rear; disconnect the negative battery terminal; lift the vehicle to a suitable height using a lift or jack with safety stands.
Drain the transmission fluid, remove the drive shaft/half-shaft and transmission, then take out the old pressure plate, friction disc, and release bearing.
Clean the flywheel surface, pilot bearing bore, and clutch housing mounting surface. Inspect the flywheel for cracks and check if the end runout exceeds the limit (usually ≤0.1mm); inspect the pilot bearing for seizing and replace if necessary.
Clean the contact surfaces of the flywheel and crankshaft. Apply thread locker (e.g., Loctite 243) to new flywheel bolts, then tighten them in a star pattern in 2-3 stages to the specified torque (63Nm for common 1.8L models; refer to the vehicle manual for exact values).
Verify the flywheel end runout to ensure it meets requirements.
Centering: Place the friction disc on the flywheel and insert the centering mandrel through the friction disc spline hole and flywheel pilot bearing bore to ensure concentricity between the friction disc and flywheel.
Direction Confirmation: Install the friction disc with the damper spring side facing the pressure plate and the short spline hub side facing the flywheel (or follow the "Flywheel Side" marking).
Pressure Plate Fixing: Align the pressure plate with the flywheel locating pins, hand-tighten the bolts, then tighten them diagonally in 3 stages: first pre-tighten (5-9Nm), second semi-tighten (15-20Nm), and third final-tighten to the specified torque (25Nm for common models; refer to the vehicle manual for exact values). Pneumatic impact wrenches are prohibited.
Remove the centering mandrel and check if the friction disc rotates freely.
Apply a small amount of high-temperature grease to the release bearing and install it on the release fork, ensuring the circlip is properly seated.
Check the concentricity of both ends of the release fork shaft, install the return spring, and ensure smooth fork movement.
The installation position of the release fork shaft lever should be 195-205mm from the fixed cable nut bracket (refer to the vehicle manual for exact values).
Clean the transmission input shaft splines and apply a small amount of clutch spline grease. Align the transmission input shaft with the friction disc spline hole and push it in slowly; use a rubber mallet to lightly tap the transmission case if necessary.
Install the transmission mounting bolts and tighten them diagonally in 2-3 stages to the specified torque (37Nm for common models; refer to the vehicle manual for exact values).
Connect the drive shaft/half-shaft, tighten the nuts to the specified torque, install the transmission oil pan, and fill with new transmission fluid to the specified level.
Install the clutch master cylinder and slave cylinder, connect the hydraulic lines, and ensure no leaks at the joints.
Tighten the slave cylinder mounting bolts to the specified torque (15Nm for common models).
Two-Person Cooperative Method: One person depresses the clutch pedal 3-5 times continuously and holds it down; the other opens the slave cylinder bleeder valve to release air, closes the valve, and then the first person releases the pedal. Repeat until no air bubbles are present in the discharged fluid, and replenish brake fluid to the specified level in the reservoir simultaneously.
Vacuum Bleeding Method: Connect a vacuum tool to the slave cylinder bleeder valve, evacuate to below -0.08MPa, open the valve to release air, close the valve, and stop evacuation. Repeat until no air bubbles are present.
After bleeding, check for leaks in the hydraulic lines.
Adjust the clutch pedal free travel to the specified range (15-25mm for common models), which can be achieved by adjusting the master cylinder push rod length or slave cylinder push rod position.
Check if the pedal returns smoothly without seizing.
Start the engine and test clutch disengagement and engagement at idle:
Disengagement Test: Depress the pedal and shift into all gears; there should be no gear grinding, and shifting should be smooth.
Engagement Test: Release the pedal slowly; the vehicle should start smoothly without slipping or shuddering.
Road Test: Test the clutch operation during low-speed starting, gear shifting, and high-speed driving; check for abnormal noise, slipping, or incomplete disengagement.
Cleanliness: Keep the friction disc, pressure plate, and flywheel surface clean during installation to avoid oil contamination or dust adhesion.
Lubrication: Apply an appropriate amount of grease to splines, release bearing, fork pivot points, etc. Excessive grease may cause the friction disc to slip.
Torque Application: All bolts must be tightened to the specified torque using a torque wrench; manual feel is not allowed.
One-Time Components: Replace one-time components such as flywheel bolts and release bearing circlips; do not reuse them.
Thorough Bleeding: Incomplete bleeding of the hydraulic system will result in incomplete clutch disengagement; ensure no air bubbles remain in the discharged fluid.
References：
The content regarding the installation method of Toyota manual transmission clutch kits is not directly derived from a single official document. Instead, it is compiled based on the general procedures and common vehicle specifications in Toyota's Repair Manual (TIS), combined with universal operating standards and practical experience in the automotive repair industry. The specific source explanation is as follows:
Content Alignment: The installation process (Cleaning → Centering → Diagonal Uniform Torquing → Lubrication → Bleeding → Commissioning), key precautions (e.g., flywheel end runout ≤ 0.1mm, release bearing lubrication, hydraulic system bleeding methods), and torque parameters (e.g., flywheel bolts 63Nm, pressure plate bolts 25Nm) in the content are consistent with the core requirements of the clutch installation chapter for manual transmission models in Toyota's Official Repair Manual (Toyota Technical Information System, TIS).
Vehicle Reference: The manual provides detailed regulations on clutch installation steps, torque values, centering tool models (SST), etc., for different models (such as Corolla, Camry, RAV4). The general process in the content is a summary of the common operations across these models.
Operating Standards: Practices such as applying high-temperature grease to the release bearing, confirming the direction of the friction disc (damper spring side facing the pressure plate), and the two-person cooperative/vacuum bleeding methods for hydraulic systems are universal operating specifications in the automotive repair industry, widely used in clutch installation for various manual transmission vehicles.
Safety Requirements: Vehicle safety preparations before installation (engaging the parking brake, placing wheel chocks, disconnecting the negative battery terminal, etc.) and tool selection (torque wrench accuracy requirements, use of centering mandrels) are basic safety and operational guidelines in the repair industry.
Not Excerpted from a Single Document: The content does not specify the exact vehicle model, year, or manual page number. Additionally, some parts (such as the common torque reference table) are a compilation of parameters from different models, so it can be determined that they are not directly copied from a specific Toyota official repair manual.
Integration of Practical Experience: The content includes detailed tips from repair practices (e.g., replacing one-time use bolts, avoiding pneumatic impact wrenches). Although these tips comply with official requirements, they may be scattered as "Precautions" in the manual rather than integrated centrally.
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