CLUTCH UNIT(for EC69) INSTALLATION

PROCEDURE


  1. 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.

  2. INSTALL CLUTCH DISC ASSEMBLY


    1. A0049AQE01
      Text in Illustration
      *1 Clutch Disc Assembly
      *2 Flywheel Sub-assembly

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

      SST
      09301-00210

      Note

      Insert clutch disc assembly in the correct direction.

  3. INSTALL CLUTCH COVER ASSEMBLY


    1. A004AR1E02
      Text in Illustration
      *a Matchmark
      *b Temporarily Tighten

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

    2. Using SST, center the clutch disc assembly, and following the procedure shown in the illustration, tighten the 6 bolts in order, starting with the bolt located near the knock pin at the top.

      SST
      09301-00210
      Torque:
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

      Tech Tips


      • 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.

  4. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY


    1. A0049PQ

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

      Maximum non-alignment
      0.5 mm (0.0197 in.)
    2. A004BBWE02

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

      SST
      09333-00013

  5. 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 to a new clutch release cylinder with bearing assembly.

    3. A00492BE02
      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

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

      Torque:
      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.

      Torque:
      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 to 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 to the clutch release cylinder with bearing assembly.

      Torque:
      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.

      Text in Illustration
      A0049LZ Clutch spline grease
      Grease
      Toyota Genuine Clutch Spline Grease or equivalent

  6. 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 clutch release bleeder sub-assembly from the manual transaxle assembly.

  7. INSPECT CLUTCH PIPE LINE


    1. A0046XOE02

      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.

      SST
      09992-00242

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

  8. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


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

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

      Torque:
      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 to the clutch release bleeder sub-assembly.

      Torque:
      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. INSTALL NO. 1 CLUTCH HOUSING COVER


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

  10. INSTALL MANUAL TRANSAXLE ASSEMBLY

    Click here