CLUTCH UNIT (for 1ZR-FAE, 2ZR-FAE) INSTALLATION

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.


  1. INSTALL CLUTCH DISC ASSEMBLY

    A01IQUJE01

    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

    A01IS32E01
    Text in Illustration
    *1 Matchmark
    *2 Temporarily Install

    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  { 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. A01IT4GE01

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

      Maximum misalignment
      0.5 mm (0.0196 in.)

      If the misalignment 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. A01IR6L

      Temporarily install the clutch release cylinder to bleeder 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. A01IU7F

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

      Torque:
      23 N*m  { 229 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. A01IU6K

      Install the clutch tube boot to the manual transaxle assembly.

    5. A01INUU

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

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

    7. A01ITOK

      Using a union nut wrench, install the clutch release cylinder to bleeder 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 where a union nut wrench is combined with a torque wrench Click here.

    8. A01ISD2E02
      Text in Illustration
      *1 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. A01INUU

      Separate the clutch release cylinder to bleeder tube from the clutch release bleeder sub-assembly.

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

  6. INSPECT CLUTCH PIPE LINE

    A01IQJWE01

    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 bleeder tube.

  7. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


    1. A01INUU

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

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

      Torque:
      17 N*m  { 170 kgf*cm, 12 ft.*lbf }
    3. Using a union nut wrench, install the clutch release cylinder to bleeder tube.

      Torque:
      15 N*m  { 155 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 RELEASE BLEEDER TO FLEXIBLE HOSE TUBE


    1. A01ITRX

      for 1ZR-FAE:


      1. Using a union nut wrench, install the clutch release bleeder to flexible hose 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 where a union nut wrench is combined with a torque wrench Click here.

      2. Install the clamp to the manual transaxle with the bolt.

        Torque:
        12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    2. A01IQTQ

      for 2ZR-FAE:


      1. Using a union nut wrench, install the clutch release bleeder to flexible hose 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 where a union nut wrench is combined with a torque wrench Click here.

      2. Install the 2 clamps to the manual transaxle with the 2 bolts.

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


    1. for 1ZR-FAE:

      Install the manual transaxle assembly Click here.

    2. for 2ZR-FAE:

      Install the manual transaxle assembly Click here.