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.

INSTALL CLUTCH DISC ASSEMBLY

Text in Illustration
*1	Clutch Disc Assembly
*2	Flywheel Sub-assembly

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.

INSTALL CLUTCH COVER ASSEMBLY
1. Text in Illustration
  
  *a Matchmark
  
  *b Temporarily
  
  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.
  
  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.
  SST
  
  09301-00210
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 FLEXIBLE HOSE BRACKET
1. Install the clutch flexible hose bracket to the manual transaxle assembly with the bolt.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
TEMPORARILY TIGHTEN BLEEDER CLUTCH RELEASE TUBE
1. Temporarily tighten the bleeder clutch release tube to a new clutch release with bearing cylinder assembly.
INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY
1. Install the clutch release with bearing cylinder assembly to the manual transaxle assembly with 3 new bolts.
  
  Torque:
  
  23 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 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 spline grease adheres to the clutch release with bearing cylinder assembly.
  - The clutch release with bearing cylinder assembly cannot be disassembled.
2. Apply clutch spline grease to the input shaft spline.
  
  Grease
  
  Toyota Genuine Clutch Spline Grease or equivalent
INSTALL CLUTCH TUBE BOOT
1. Install the clutch tube boot to the manual transaxle assembly.
INSTALL RELEASE CYLINDER BLEEDER PLUG
1. Install the release cylinder bleeder plug to the clutch release bleeder sub-assembly.
  
  Torque:
  
  8.4 N*m { 86 kgf*cm, 74 in.*lbf }
INSTALL RELEASE CYLINDER BLEEDER PLUG CAP
1. Install the release cylinder bleeder plug cap to the release cylinder bleeder plug.
TEMPORARILY TIGHTEN CLUTCH RELEASE BLEEDER SUB-ASSEMBLY
1. Temporarily tighten the bleeder clutch release tube to the clutch release bleeder sub-assembly.
2. Temporarily install the clutch release bleeder sub-assembly to the manual transaxle assembly with the 2 bolts.
FULLY TIGHTEN BLEEDER CLUTCH RELEASE TUBE
1. Using a union nut wrench 10 mm, fully tighten the bleeder clutch release tube to the clutch release with bearing cylinder assembly.
  
  Torque:
  
  15 N*m { 155 kgf*cm, 11 ft.*lbf }
  
  Note
  
  Use the formula to calculate special torque values for situations when the union nut wrench is combined with a torque wrench Click here.
REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY
1. Separate the bleeder clutch release tube from the clutch release bleeder sub-assembly.
2. Remove the 2 bolts and the clutch release bleeder sub-assembly from the manual transaxle assembly.
INSPECT CLUTCH PIPE LINE
1. Using SST, apply pressure of 0.1 MPa (1.02 kgf/ cm², 14.5 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 bleeder clutch release tube.
INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY
1. Temporarily tighten the bleeder clutch release tube to the clutch release bleeder sub-assembly.
2. Install the clutch release bleeder sub-assembly to the manual transaxle assembly with the 2 bolts.
  
  Torque:
  
  17 N*m { 170 kgf*cm, 12 ft.*lbf }
3. Using a union nut wrench 10 mm, fully tighten the bleeder clutch release tube to the clutch release bleeder sub-assembly.
  
  Torque:
  
  15 N*m { 155 kgf*cm, 11 ft.*lbf }
  
  Note
  
  Use the formula to calculate special torque values for situations when the union nut wrench is combined with a torque wrench Click here.
INSTALL BLEEDER CLUTCH RELEASE TUBE
1. Install the bleeder clutch release tube to the manual transaxle assembly 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 to the clutch release bleeder sub-assembly.
  
  Torque:
  
  15 N*m { 155 kgf*cm, 11 ft.*lbf }
  
  Note
  
  Use the formula to calculate special torque values for situations when the union nut wrench is combined with a torque wrench Click here.
INSTALL NO. 1 CLUTCH HOUSING COVER
1. Install the No. 1 clutch housing cover to the manual transaxle assembly.
INSTALL MANUAL TRANSAXLE ASSEMBLY

Click here

Text in Illustration
*a	Matchmark
*b	Temporarily