Installation

EB60 MANUAL TRANSMISSION / TRANSAXLE: MANUAL TRANSAXLE ASSEMBLY: INSTALLATION

NOTICE:
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 from the moving section could damage the seal of the clutch release with bearing cylinder, possibly causing clutch fluid leaks.

1. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY

(a) Coat a new O-ring with gear oil and install it to the speedometer driven hole cover sub-assembly.

(b) Install the speedometer driven hole cover sub-assembly to the transaxle case with the bolt.

Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

2. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the wire harness clamp bracket with the bolt.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

3. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY Installation

4. INSPECT CLUTCH PIPE LINE Installation

5. INSTALL CLUTCH ACCUMULATOR ASSEMBLY

Installation

6. INSTALL REAR ENGINE MOUNTING BRACKET

(a) Install the rear engine mounting bracket with the 4 bolts.

Torque : 45 Nm (459 kgf-cm, 33 ft-lbf)

7. INSTALL ENGINE MOUNTING BRACKET LH

(a) Apply adhesive to the 4 bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the engine mounting bracket LH with the 4 bolts.

Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)

8. INSTALL FRONT ENGINE MOUNTING BRACKET

(a) Install the front engine mounting bracket with the 3 bolts.

Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)

9. INSTALL MANUAL TRANSAXLE ASSEMBLY

(a) Make sure that the dowel pins are not loose, bent, damaged or scratched.





(b) Align the input shaft with the clutch disc, and then install the manual transaxle to the engine with the contact surfaces of the engine and transaxle flat against each other.

(c) Temporarily install the 10 bolts.

NOTICE:
Insert the dowel pins into the dowel holes securely so that the end face of the transaxle assembly fits close against the engine assembly before tightening the bolts.

(d) Tighten the 3 bolts in the sequence shown in the illustration.





Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)

HINT
Each bolt length is indicated below.

60 mm (2.36 in.) for bolt 1 and 2

74.5 mm (2.93 in.) for bolt 3

(e) Tighten the 7 bolts.





for bolt A and B - Torque : 46 Nm (469 kgf-cm, 34 ft-lbf)

for bolt C - Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

HINT
Each bolt length is indicated below.

60 mm (2.36 in.) for bolt A

65 mm (2.56 in.) for bolt B

32 mm (1.26 in.) for bolt C

10. INSTALL CONTROL CABLE BRACKET ASSEMBLY

(a) Install the control cable bracket with the 3 bolts.

Torque : 17 Nm (173 kgf-cm, 13 ft-lbf)

11. CONNECT WIRE HARNESS

(a) Connect the back-up light switch connector and attach the harness clamp.

(b) Install the transmission wire with the bolt.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

12. INSTALL ENGINE AND TRANSAXLE

Installation