CLUTCH UNIT(for 2AR-FE) INSTALLATION

CAUTION / NOTICE / HINT

Note

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

PROCEDURE


  1. INSTALL CLUTCH DISC ASSEMBLY

    A01V9BDC01
    *1 Clutch Disc Assembly

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

      SST
      09301-00210

      Note

      Insert the clutch disc assembly in the correct direction.

  2. INSTALL CLUTCH COVER ASSEMBLY

    A01V88OC01
    *a Matchmark

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

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

      SST
      09301-00210
      Torque:
      19 N*m  { 194 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. A01V8C8

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

      Maximum non-alignment
      0.5 mm (0.0196 in.)
    2. A01VA41

      If the alignment is more than the maximum, using SST, adjust the diaphragm spring tip alignment.

      SST
      09333-00013

  4. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY


    1. A01V7ZZ

      Temporarily install the clutch release cylinder to flexible hose 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. A01V78S

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

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

      Note


      • The clutch release with bearing cylinder 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 with bearing cylinder fits securely with the transaxle during installation. The first bolt should be tightened by hand while holding the clutch release with bearing cylinder.

      • Make sure that none of the clutch spline grease adheres to the clutch release with bearing cylinder.

      • The clutch release with bearing cylinder cannot be disassembled.

    4. A01V76M

      Install the clutch tube boot to the manual transaxle assembly.

    5. A01V7FG

      Temporarily install the clutch release cylinder to flexible hose tube to the clutch release bleeder sub-assembly.

    6. A01VATP

      Temporarily install the clutch release bleeder sub-assembly with the 2 bolts.

    7. A01VAF9

      Using a union nut wrench, install the clutch release cylinder to flexible hose tube to the clutch release with bearing cylinder assembly.

      Torque:
      15 N*m  { 153 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.

    8. A01VB2EC01
      A01V9RL Clutch Spline Grease

      Apply clutch spline grease to the input shaft spline.

      Grease
      Toyota Genuine Clutch Spline Grease or equivalent

  5. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


    1. A01V6XW

      Using a union nut wrench, disconnect the clutch release cylinder to flexible hose tube from the clutch release bleeder sub-assembly.

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

  6. INSPECT CLUTCH PIPE LINE

    A01VAUFN01

    1. Using SST, apply a 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 flexible hose tube.

  7. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


    1. A01V6XW

      Temporarily install the clutch release cylinder to flexible hose tube to the clutch release bleeder sub-assembly.

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

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

    3. Using a union nut wrench, install the clutch release cylinder to flexible hose tube.

      Torque:
      15 N*m  { 153 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.

  8. INSTALL CLUTCH TUBE


    1. Temporarily install the bleeder to accumulator tube labeled A and accumulator to flexible hose tube labeled B.

    2. A01V80WC01
      *a Paint Mark

      Using a 10 mm union nut wrench, tighten the bleeder to accumulator tube labeled A and accumulator to flexible hose tube labeled B.

      Torque:
      15 N*m  { 153 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.

    3. Install the clamp with the bolt.

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

      Tech Tips

      Align the clamp and paint mark as shown in the illustration and install the clamp.

  9. INSTALL MANUAL TRANSAXLE ASSEMBLY

    for EB63:

    Click here

    for EB63F:

    Click here