CLUTCH UNIT(for EC6A) 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

INSTALL CLUTCH DISC ASSEMBLY
1. *1 Clutch Disc Assembly
  
  *a Flywheel Sub-assembly Side
  
  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.
INSTALL CLUTCH COVER ASSEMBLY
1. *a Temporarily
  
  *b Matchmark
  
  Align the matchmark on the clutch cover assembly with the one on the flywheel sub-assembly.
2. Using SST, following the procedure shown in the illustration, fully install 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, fully install 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 fully install the bolts.
INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
1. Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.
  
  Maximum Non-alignment
  
  0.5 mm (0.0197 in.)
2. If the alignment is not as specified, using SST, adjust the diaphragm spring tip alignment.
  
  SST
  
  09333-00013
INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY
1. Temporarily install 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 to the manual transaxle assembly.
  
  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 while 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 to the manual transaxle assembly.
5. Temporarily install the clutch release cylinder to bleeder tube to the clutch release bleeder sub-assembly.
6. Temporarily install the clutch release bleeder sub-assembly with the 2 bolts.
7. *a Torque Wrench Fulcrum Length
  
  Using a 10 mm union nut wrench, install the clutch release cylinder to bleeder tube to the clutch release with bearing cylinder assembly.
  
  Torque:
  
  Specified tightening torque
  
  15.2 N*m { 155 kgf*cm, 11 ft.*lbf }
  Tech Tips
  
  Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
  
  Click here
  
  When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):
  
  13 N*m (133 kgf*cm, 10 ft.*lbf)
8. Clutch Spline grease
  
  Apply clutch spline grease to the input shaft splines.
  
  Grease
  
  Toyota Genuine Clutch Spline Grease or equivalent
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.
INSPECT CLUTCH PIPE LINE
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.
INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY
1. Temporarily connect the clutch release cylinder to bleeder tube to the clutch release bleeder sub-assembly.
2. Install the clutch release bleeder sub-assembly with the 2 bolts.
  
  Torque:
  
  16.7 N*m { 170 kgf*cm, 12 ft.*lbf }
3. Using a 10 mm union nut wrench, connect the clutch release cylinder to bleeder tube.
  
  Torque:
  
  Specified tightening torque
  
  15.2 N*m { 155 kgf*cm, 11 ft.*lbf }
  Tech Tips
  - Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
    
    Click here
  - When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):
    
    13 N*m (133 kgf*cm, 10 ft.*lbf)
INSTALL BLEEDER CLUTCH RELEASE TUBE
*a Torque Wrench Fulcrum Length
1. Using a 10 mm union nut wrench, connect the bleeder clutch release tube to the clutch release bleeder sub-assembly.
  
  Torque:
  
  Specified tightening torque
  
  15.2 N*m { 155 kgf*cm, 11 ft.*lbf }
  Tech Tips
  - Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
    
    Click here
  - When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):
    
    13 N*m (133 kgf*cm, 10 ft.*lbf)
2. Install the bolt and bleeder clutch release tube to the manual transaxle assembly.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL MANUAL TRANSAXLE ASSEMBLY

Click here

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

*a	Temporarily
*b	Matchmark