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CLUTCH UNIT(for EC62) INSTALLATION

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PROCEDURE


  1. Click here

    PRECAUTION

    Note:

    When the transaxle is removed, be sure to use a new clutch release cylinder with bearing assembly and new installation bolts. Removal of the transaxle allows the compressed clutch release cylinder with bearing assembly to return to its original position, and dust from the moving section could damage the seal of the clutch release cylinder with bearing assembly, possibly causing clutch fluid leaks.

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    INSTALL CLUTCH DISC ASSEMBLY


    1. A0048SFE03

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

      Table 1. Text in Illustration
      *1 Clutch Disc Assembly
      *2 Flywheel Sub-assembly
      09301-00210
      Note:

      Insert clutch disc assembly in the correct direction.

  3. Click here

    INSTALL CLUTCH COVER ASSEMBLY


    1. A0049OTE02

      Align the matchmark on the clutch cover assembly with that on the flywheel sub-assembly.

      Table 2. Text in Illustration
      *a Matchmark
      *b Temporarily

    2. Following the procedures shown in the illustration, tighten the 6 bolts in order, starting with the bolt located near the knock pin at the top.

      09301-00210
      19 N*m 195 kgf*cm 14 ft.*lbf
      Tip:

      • 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 disc is in the center, and tighten the bolts.

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    INSPECT AND ADJUST CLUTCH COVER ASSEMBLY


    1. A004BCU

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

      Maximum non-alignment
      0.5 mm (0.0197 in.)
    2. A004A2EE02

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

      09333-00013
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    INSTALL CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY


    1. Clean and degrease all installation surfaces for the clutch release cylinder with bearing assembly.

    2. Temporarily tighten the clutch release cylinder to bleeder tube onto a new clutch release cylinder with bearing assembly.

    3. A0049R0E01

      Install the clutch release cylinder with bearing assembly to the manual transaxle assembly with 3 new bolts.

      Table 3. Text in Illustration
      *1 Clutch Release Cylinder to Bleeder Tube
      *2 Clutch Release Cylinder with Bearing Assembly
      *3 Clutch Tube Boot
      *4 Clutch Release Bleeder Sub-assembly
      23 N*m 229 kgf*cm 17 ft.*lbf
      Note:

      • The clutch release cylinder with bearing assembly and installation bolts cannot be reused and must be replaced with new ones.

      • Clean and degrease all installation surfaces and make sure the clutch release cylinder with bearing assembly fits securely with the transaxle during installation. The first bolt should be tightened with a hand holding the clutch release cylinder with bearing assembly.

      • Ensure that none of the clutch spline grease adheres to the clutch release cylinder with bearing assembly.

      • The clutch release cylinder with bearing assembly cannot be disassembled.

    4. Install the clutch tube boot to the manual transaxle assembly.

    5. Install the release cylinder bleeder plug to the clutch release bleeder sub-assembly.

      8.4 N*m 86 kgf*cm 74 in.*lbf

    6. Install the release cylinder bleeder plug cap to the release cylinder bleeder plug.

    7. Temporarily tighten the clutch release cylinder to bleeder tube onto the clutch release bleeder sub-assembly.

    8. Temporarily tighten the 2 bolts and install the clutch release bleeder sub-assembly to the manual transaxle assembly.

    9. Using a union nut wrench (10 mm), fully tighten the clutch release cylinder to bleeder tube onto the clutch release cylinder with bearing assembly.

      15 N*m 155 kgf*cm 11 ft.*lbf
      Note:

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Click here).

    10. A0049L8

      Apply clutch spline grease to the input shaft spline.

      Table 4. Text in Illustration
      A0049LZ Clutch spline grease
      Grease
      Toyota Genuine Clutch Spline Grease or equivalent
  6. Click here

    REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


    1. Disconnect the clutch release cylinder to bleeder tube from the clutch release bleeder sub-assembly.

    2. Remove the 2 bolts and the clutch release bleeder sub-assembly from the manual transaxle assembly.

  7. Click here

    INSPECT CLUTCH PIPE LINE


    1. A0046XOE03

      Using SST, apply pressure of 100 kPa (1.02 kgf/cm2, 14.5 psi) to the clutch pipe location shown in the illustration and confirm that pressure is maintained for 15 seconds or more.

      09992-00242

      If the pressure drops, replace the clutch release cylinder to bleeder tube.

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    INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


    1. Temporarily tighten the clutch release cylinder to bleeder tube onto the clutch release bleeder sub-assembly.

    2. Install the clutch release bleeder sub-assembly to the manual transaxle assembly with the 2 bolts.

      17 N*m 170 kgf*cm 12 ft.*lbf

    3. Using a union nut wrench (10 mm), fully tighten the clutch release cylinder to bleeder tube onto the clutch release bleeder sub-assembly.

      15 N*m 155 kgf*cm 11 ft.*lbf
      Note:

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Click here).

  9. Click here

    INSTALL CLUTCH FLEXIBLE HOSE BRACKET


    1. Install the clutch flexible hose bracket to the manual transaxle assembly with the bolt.

      19 N*m 194 kgf*cm 14 ft.*lbf
  10. Click here

    INSTALL CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE


    1. Using a union nut wrench (10 mm), install the clutch release cylinder to flexible hose tube to the clutch release bleeder sub-assembly.

      15 N*m 155 kgf*cm 11 ft.*lbf
      Note:

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Click here).

    2. Install the 2 tube clamps to the manual transaxle assembly with the 2 bolts.

      19 N*m 194 kgf*cm 14 ft.*lbf
  11. Click here

    INSTALL NO. 1 CLUTCH HOUSING COVER


    1. Install the No. 1 clutch housing cover to the manual transaxle assembly.

  12. Click here

    INSTALL MANUAL TRANSAXLE ASSEMBLY

    (Click here)