CLUTCH UNIT(for EC69) INSTALLATION

Info Added 2017-10-06

CAUTION / NOTICE / HINT

Note

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

PROCEDURE


  1. INSTALL CLUTCH DISC ASSEMBLY

    A001WA4C03
    *1 Clutch Disc Assembly
    *2 Flywheel Sub-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

    A001UOVC02
    *a Matchmarks
    *b Temporarily Tighten

    1. Align the matchmarks 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. A001XEO

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

      Maximum Non-alignment
      0.5 mm (0.0197 in.)
    2. A001V9HE02

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

      SST
      09333-00013

  4. INSTALL CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY


    1. A001X6O

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

      Note

      Do not allow any foreign matter such as dirt or dust to enter the clutch release cylinder to flexible hose tube from the connecting part.

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

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

      Torque:
      22.5 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 that the clutch release cylinder with bearing assembly fits securely with the manual transaxle assembly during installation. The first bolt should be tightened by 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 onto the manual transaxle assembly.

    5. A001XHP

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

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

    7. A001SWXC01
      *a Torque Wrench Fulcrum Length

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

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

      Note

      Do not kink or damage the clutch release cylinder to flexible hose tube.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

    8. A001TVHC01
      B00495X Clutch Spline Grease

      Apply clutch spline grease to the input shaft splines.

      Grease
      Toyota Genuine Clutch Spline Grease or equivalent

  5. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


    1. A001XHP

      Separate 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

    A001W14E01

    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 flexible hose tube.

  7. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


    1. A001UWHC01
      *a Torque Wrench Fulcrum Length

      Temporarily tighten the clutch release cylinder to flexible hose 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 flexible hose tube.

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

      Note


      • Do not kink or damage the clutch release cylinder to flexible hose tube.

      • Do not allow any foreign matter such as dirt or dust to enter the clutch release cylinder to flexible hose tube from the connecting part.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

  8. INSTALL BLEEDER CLUTCH RELEASE TUBE

    A001T83C01
    *a Torque Wrench Fulcrum Length

    1. Using a 10 mm union nut wrench, install 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 }

      Note


      • Do not kink or damage the bleeder clutch release tube.

      • Do not allow any foreign matter such as dirt or dust to enter the bleeder clutch release tube from the connecting part.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

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

      Torque:
      11.8 N*m  { 120 kgf*cm, 9 ft.*lbf }

  9. INSTALL MANUAL TRANSAXLE ASSEMBLY


    • When Not Using the Engine Support Bridge:

      Click here

    • When Using the Engine Support Bridge:

      Click here