CLUTCH UNIT(for 3ZR-FE, 3ZR-FAE) 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

    C200452C01

    *1

    Clutch Disc Assembly

    *a

    Flywheel side

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

      09301-00210

      Note:

      Insert the clutch disc assembly in the correct direction.

  2. INSTALL CLUTCH COVER ASSEMBLY

    C280397C01

    *a

    Matchmark

    *b

    Temporarily install

    1. Align the matchmarks 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.

      09301-00210

      19 N*m

      194 kgf*cm

      14 ft.*lbf

      Tip:
      • 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. C205506E01

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

      Maximum non-alignment

      0.5 mm (0.0196 in.)

      If the alignment is more than the maximum, using SST, adjust the diaphragm spring tip alignment.

      09333-00013

  4. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    1. C197022

      Temporarily install the clutch release cylinder to flexible hose 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. C199331

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

      23 N*m

      235 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. C199330

      Install the clutch tube boot to the manual transaxle assembly.

    5. C199329

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

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

    7. C202447

      Using a union nut wrench, install the clutch release cylinder to hoe tube to the clutch release with bearing cylinder assembly.

      15 N*m

      153 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 hereClick hereClick hereClick hereClick here).

    8. C199336C02
      V100135

      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. C199329

      Using a union nut wrench, disconnect 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

    C199335E01
    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.

      09992-00242

      If the pressure drops, replace the clutch release cylinder to flexible hose tube.

  7. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    1. C199329

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

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

      17 N*m

      173 kgf*cm

      13 ft.*lbf

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

      15 N*m

      153 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 hereClick hereClick hereClick hereClick here).

  8. INSTALL CLUTCH TUBE

    1. Temporarily install the bleeder to accumulator tube labeled A and accumulator to flexible hose tube labeled B.

    2. C280409C01

      *a

      Paint Mark

      Using a 10 mm union nut wrench, tighten the bleeder to accumulator tube labeled A and accumulator to flexible hose tube labeled B.

      15 N*m

      153 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 hereClick hereClick hereClick hereClick here).

    3. Install the clamp with the bolt.

      12 N*m

      122 kgf*cm

      9 ft.*lbf

      Tip:

      Align the clamp and paint mark as shown in the illustration and install the clamp.

  9. INSTALL MANUAL TRANSAXLE ASSEMBLY