Installation

CLUTCH: CLUTCH UNIT: 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 CLUTCH DISC ASSEMBLY





(a) Insert SST into the clutch disc assembly, then insert them both into the flywheel sub-assembly.

SST : 09301-00210

NOTICE:
Insert the clutch disc assembly in the correct direction.

2. INSTALL CLUTCH COVER ASSEMBLY





(a) Align the matchmark on the clutch cover assembly with that on the flywheel sub-assembly.

(b) Following the procedure 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 Nm (195 kgf-cm, 14 ft-lbf)

HINT
* 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

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





Maximum non-alignment:

0.5 mm (0.0197 in.)

(b) If the alignment is not as specified, using SST, adjust the diaphragm spring tip alignment.





SST : 09333-00013

4. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

(a) Temporarily tighten the clutch release cylinder to bleeder tube onto a new clutch release with bearing cylinder assembly.





(b) Clean and degrease all installation surfaces for the clutch release with bearing cylinder assembly.

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





Torque : 23 Nm (229 kgf-cm, 17 ft-lbf)

NOTICE:
* 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 that 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.
* 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.

(d) Install the clutch tube boot onto the transaxle case.





(e) Temporarily tighten the clutch release cylinder to bleeder tube onto the clutch release bleeder sub-assembly.





(f) Temporarily tighten the 2 bolts and install the clutch release bleeder.

(g) Using a union nut wrench (10 mm), install the clutch release cylinder to bleeder tube.





without a union nut wrench - Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)

with a union nut wrench - Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)

NOTICE:
* Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
* This torque value is effective when the union nut wrench is parallel to the torque wrench.

(h) Apply clutch spline grease to the input shaft splines.





Sealant:

Toyota Genuine Clutch Spline Grease or equivalent

5. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

(a) Separate the clutch release cylinder to bleeder tube from the clutch release bleeder.





(b) Remove the 2 bolts and the clutch release bleeder.

6. INSPECT CLUTCH PIPE LINE





(a) Using SST, apply pressure of 0.1 MPa 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

(a) Temporarily tighten the clutch release cylinder to bleeder tube onto the clutch release bleeder.





(b) Install the 2 bolts and clutch release bleeder.

Torque : 17 Nm (170 kgf-cm, 12 ft-lbf)

(c) Using a union nut wrench (10 mm), install the clutch release cylinder to bleeder tube.





without a union nut wrench - Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)

with a union nut wrench - Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)

NOTICE:
* Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
* This torque value is effective when the union nut wrench is parallel to the torque wrench.

8. INSTALL CLUTCH ORIFICE ASSEMBLY (w/ Clutch Orifice Assembly)

(a) Install the 2 bolts and clutch orifice assembly.





Torque : 19 Nm (192 kgf-cm, 14 ft-lbf)

(b) Using a union nut wrench (10 mm), install the clutch release bleeder tube and orifice to flexible hose tube.





without a union nut wrench - Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)

with a union nut wrench - Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)

NOTICE:
* Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
* This torque value is effective when the union nut wrench is parallel to the torque wrench.

9. INSTALL CLUTCH LINE (w/o Clutch Orifice Assembly)

(a) Using a union nut wrench (10 mm), install the clutch line.





without a union nut wrench - Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)

with a union nut wrench - Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)

NOTICE:
* Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
* This torque value is effective when the union nut wrench is parallel to the torque wrench.

(b) Install the bolt and clutch line.

Torque : 19 Nm (192 kgf-cm, 14 ft-lbf)

10. INSTALL MANUAL TRANSAXLE ASSEMBLY

(a) Install the manual transaxle assembly Installation.