CLUTCH UNIT (for EE63) INSTALLATION

Note

When the transaxle 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, and dust could damage the seal of the clutch release with bearing cylinder assembly, possibly causing clutch fluid leaks.


  1. INSTALL CLUTCH DISC ASSEMBLY


    1. A0119ZVE04
      Text in Illustration
      *1 Clutch disc
      *2 Flywheel

      Insert SST into the clutch disc assembly, and 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


    1. A011B7AE02
      Text in Illustration
      *a Temporarily
      *b Matchmark

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

    2. Following the procedures 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.

  3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY


    1. A011AOD

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

      Maximum non-alignment
      0.5 mm (0.020 in.)
    2. A011BXJE01

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

      SST
      09333-00013

  4. INSTALL CLUTCH FLEXIBLE HOSE BRACKET


    1. Install the clutch flexible hose bracket with the bolt.

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

  5. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY


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

    2. A011BWO

      Temporarily tighten the bleeder clutch release tube onto the clutch release with bearing cylinder assembly.

    3. A0119UV

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

      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 the clutch release with bearing cylinder assembly fits securely with the transaxle during installation. The first bolt should be tightened by hand the clutch release with bearing cylinder assembly when installing.

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

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

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

    4. Install the clutch tube boot onto the transaxle.

    5. Install the release cylinder bleeder plug onto the clutch release bleeder.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    6. Install the release cylinder bleeder plug cap.

    7. A0119X3E01
      Text in Illustration
      *1 Bleeder clutch release tube
      *2 Clutch release bleeder

      Temporarily tighten the bleeder clutch release tube onto the clutch release bleeder.

    8. Temporarily tighten the 2 bolts and install the clutch release bleeder.

    9. A0117M9

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

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

      Note

      Use the formula to calculate special torque values for situations when union nut wrench is combined with a torque wrench Click here.

  6. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


    1. Separate the bleeder clutch release tube from the clutch release bleeder.

    2. Remove the 2 bolts and the clutch release bleeder.

  7. INSPECT CLUTCH PIPE LINE

    A0119YKE01

    1. Using SST, apply pressure of 0.1 MPa 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 bleeder clutch release tube.

  8. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


    1. A0119X3E01
      Text in Illustration
      *1 Bleeder clutch release tube
      *2 Clutch release bleeder

      Temporarily tighten the bleeder clutch release tube onto the clutch release bleeder.

    2. Install the 2 bolts and clutch release bleeder.

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

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

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

      Note

      Use the formula to calculate special torque values for situations when union nut wrench is combined with a torque wrench Click here.

  9. INSTALL BLEEDER CLUTCH RELEASE TUBE


    1. Install the bleeder clutch release tube with the bolt.

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

    2. Using a union nut wrench 10 mm, install the bleeder clutch release tube.

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

      Note

      Use the formula to calculate special torque values for situations when union nut wrench is combined with a torque wrench Click here.

  10. INSTALL NO. 1 CLUTCH HOUSING COVER


    1. Install the No. 1 clutch housing cover onto the transaxle.

  11. INSTALL MANUAL TRANSAXLE ASSEMBLY


    1. Install the manual transaxle assembly Click here.