CLUTCH UNIT(for EC61) INSTALLATION

CAUTION / NOTICE / HINT

Note

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

PROCEDURE


  1. INSTALL CLUTCH DISC ASSEMBLY

    A01TA6RC01
    *1 Clutch Disc Assembly
    *a Flywheel Sub-assembly Side

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

      SST
      09301-00210

      Note

      Insert the clutch disc assembly in the correct direction.

  2. INSTALL CLUTCH COVER ASSEMBLY

    A01T8Q5C02
    *a Temporarily
    *b Matchmark

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

    2. 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:
      19.1 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 clutch disc assembly is in the center, and tighten the bolts.

  3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY


    1. A01TCNP

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

      Maximum Non-alignment
      0.5 mm (0.0197 in.)
    2. A01TCREN02

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

      SST
      09333-00013

  4. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY


    1. A01TD9H

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

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

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

      Torque:
      22.5 N*m  { 229 kgf*cm, 17 ft.*lbf }

      Note


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

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

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

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

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

    5. A01TBX9

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

    6. Temporarily tighten the 2 bolts and install the clutch release bleeder sub-assembly.

    7. A01TC2C

      Using a 10 mm union nut wrench, install the clutch release cylinder to bleeder tube to the clutch release with bearing cylinder assembly.

      Torque:
      15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note


      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

      • Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a union nut wrench.

        Click here

    8. A01TDAYC01
      A01TCE3 Clutch spline grease

      Apply clutch spline grease to the input shaft splines.

      Sealant
      Toyota Genuine Clutch Spline Grease or equivalent

  5. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


    1. A01TBX9

      Separate 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.

  6. INSPECT CLUTCH PIPE LINE

    A01TD3LN01

    1. Using SST, apply pressure of 100 kPa (1.0 kgf/cm2, 15 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.

  7. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


    1. A01TBX9

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

    2. Install the 2 bolts and clutch release bleeder sub-assembly.

      Torque:
      16.7 N*m  { 170 kgf*cm, 12 ft.*lbf }

    3. Using a 10 mm union nut wrench, install the clutch release cylinder to bleeder tube.

      Torque:
      15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note


      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

      • Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a union nut wrench.

        Click here

  8. INSTALL BLEEDER CLUTCH RELEASE TUBE

    A01TBJJ

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

      Torque:
      15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note


      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

      • Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a union nut wrench.

        Click here

    2. Install the bolt and bleeder clutch release tube to the manual transaxle assembly.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  9. INSTALL MANUAL TRANSAXLE ASSEMBLY

    Click here