5. Pack the inside of the throwout bearing collar with
high-temperature grease. Typically, collars have an
outer groove for the clutch fork. The groove should be
lightly coated with grease. Refer to Figure 7-37.
Install the throwout bearing assembly on the fork. Use
clips or retaining springs to secure the bearing to the
fork. In cases where the clutch and transmission
housings are one, it will be necessary to slide the
bearing assembly onto the hub of the front bearing
retainer first. See Figure 7-38.
6. If the clutch housing was removed, install it now.
(A clutch housing that is integral with the transmission
case is installed with the transmission.) Before instal-
lation, check for dirt or paint that could throw the
housing out of alignment. As you tighten the clutch
housing attaching bolts, make sure wires or other
vehicle components do not get pinched between the
housing and the engine block. Tighten the bolts in a
crisscross pattern and torque them to the manufac-
turer’s specifications.
7. Using a transmission jack, install the transmission as
outlined in Chapter 9, sliding the input shaft into
engagement with the throwout bearing (where clutch
housing is separate), clutch disc splines, and pilot
bearing. To align the input shaft and clutch disc
splines, use the transmission output shaft to turn the
input shaft. It may be necessary to slightly shift or
wiggle the transmission to get the input shaft through
the clutch disc and into the pilot bearing. If the pilot
shaft was used properly, the input shaft should enter
the clutch assembly without too much difficulty.
Caution: If the transmission shows any
sign of oil leakage through the front
bearing retainer, correct the leak before
installing the transmission.
If the clutch housing is part of the transmission, bolt
the unit to the back of the engine. If the clutch hous-
ing is separate, bolt the transmission case to the
housing. Start the attaching bolts as soon as the
input shaft is slid into place and the mating housing
152 Manual Drive Trains and Axles
1
3
5
4
6
Flywheel
holding tool
Tighten to
specs with
torque wrench
Pilot tool
Tighten
in crisscross
pattern in steps
Figure 7-36. The clutch cover attaching bolts should be turned
down gradually in a crisscross pattern. Push up lightly on the
pilot shaft during tightening. This will ensure the disc holds its
alignment. Bolts should be torqued to specifications. Once the
bolts are tight, remove the alignment tool. Try sliding it in and
out a few times to see that it does not bind. If it does, the trans-
mission will be difficult to install. (Toyota)
Throwout
bearing
Coat this groove
Collar Pack this recess
Figure 7-37. If the throwout bearing is not lubricated properly,
it will bind on the hub of the transmission’s front bearing
retainer, or it will wear rapidly. Apply the proper type of grease
to the places shown. (DaimlerChrysler)
Input shaft
Clutch
fork
Bearing
retaining
clip
Check
for free
movement
Move fork
Figure 7-38. In this design, the bellhousing is an integral part of
the transmission housing.The throwout bearing is placed on the
front bearing retainer hub. The clutch fork is installed, and then,
the bearing is secured to the clutch fork. Once assembled, the
clutch fork and bearing are checked for smooth operation. Note
how the bearing attaches to the clutch fork in this design
variation. (DaimlerChrysler)