CLUTCH UNIT(for EC63) 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

    A005KHFE03
    Text in Illustration
    *1 Clutch Disc
    *2 Flywheel

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

      SST
      09301-00210

      Note

      Insert clutch disc assembly in the correct direction.

  2. INSTALL CLUTCH COVER ASSEMBLY

    A005J6TE05
    Text in Illustration
    *a Temporarily
    *b Matchmark

    1. 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. A005HN1

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

      Maximum non-alignment
      0.5 mm (0.0197 in.)
    2. A005LGPE01

      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:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  5. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY


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

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

    3. A005KTFE01
      Text in Illustration
      *1 Bleeder Clutch Release Tube
      *2 Clutch Release with Bearing Cylinder
      *3 Clutch Tube Boot
      *4 Clutch Release Bleeder

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

      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 with a hand holding the clutch release with bearing cylinder.

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

      • The clutch release with bearing cylinder 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. 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. 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 where union nut wrench is combined with a torque wrench Click here.

    10. Apply clutch spline grease to the input shaft spline.

      Grease type
      Toyota Genuine Clutch Spline Grease or equivalent

  6. 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.

  7. INSPECT CLUTCH PIPE LINE

    A005LM0E02

    1. Using SST, apply pressure of 100 kPa (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.

  8. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


    1. 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 where union nut wrench is combined with a torque wrench Click here.

    4. Install the wire harness clamp bracket with the bolt.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  9. INSTALL CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE


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

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

      Note

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

    2. Install the 2 bolts and bracket onto the transaxle.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  10. INSTALL NO. 1 CLUTCH HOUSING COVER


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

  11. INSTALL MANUAL TRANSAXLE ASSEMBLY

    Click here