CLUTCH  CLUTCH UNIT(for EC60)  INSTALLATION  


CAUTION / NOTICE / HINT

NOTICE:

When the manual transaxle assembly is removed, be sure to use a new clutch release with bearing cylinder assembly and new installation bolts. Removal of the transaxle allows the compressed clutch release with bearing cylinder assembly to return to its original position. Dust from the moving section may damage the seal of the clutch release with bearing cylinder assembly, possibly causing clutch fluid leaks.


PROCEDURE

Hide 31250 1.INSTALL CLUTCH DISC ASSEMBLY

C275714C01
1.594,2.781 1.865,2.781 false 2.198,3.927 2.198,3.552 false 2.385,2.021 2.385,1.646 false 1.917,2.719 2.229,2.875 0.313,0.156 10 *1 0.833,3.354 1.146,3.51 0.313,0.156 10 *a 2.073,3.979 2.479,4.229 0.406,0.25 10 SST 2.25,2.031 2.656,2.281 0.406,0.25 10 SST
*1 Clutch Disc Assembly
*a Flywheel Sub-assembly Side


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.



Hide 31210 2.INSTALL CLUTCH COVER ASSEMBLY

C275715C01
1.021,1.344 0.667,1.969 0.667,1.969 1.063,1.354 false 2.51,1.49 2.719,1.49 false 2.552,0.208 3.188,0.385 0.635,0.177 10 1 (*a), 4 0.563,1.969 0.875,2.125 0.313,0.156 10 *b 2.74,1.406 3.115,1.604 0.375,0.198 10 SST 2.76,1.094 2.948,1.302 0.188,0.208 10 8 0.979,0.375 1.167,0.583 0.188,0.208 10 7 0.656,1.24 0.844,1.448 0.188,0.208 10 3 1.188,1.958 1.375,2.167 0.188,0.208 10 6 2.25,1.927 2.594,2.115 0.344,0.188 10 2, 5
*a Temporarily Install
*b Matchmark


a.

Align the matchmark on the clutch cover assembly with the one 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:
19.1 N*m (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 clutch disc assembly is in the center, and tighten the bolts.




Hide 31210 3.INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

a.
C275716

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

Maximum Non-alignment:

0.5 mm (0.0197 in.)



b.
C275717N01
2.24,1.219 2.448,0.719 2.448,0.719 2.625,0.719 false 2.677,0.635 3.135,0.833 0.458,0.198 10 SST

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

SST
09333-00013  


Hide 31400 4.INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

a.
C197022

Temporarily install the bleeder clutch release tube to 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:
22.5 N*m (229 kgf*cm, 17 ft.*lbf)

NOTICE:
·

The clutch release with bearing cylinder assembly 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 assembly fits securely with the manual transaxle assembly during installation. The first bolt should be tightened by hand while holding the clutch release with bearing cylinder assembly.

·

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

·

The clutch release with bearing cylinder assembly cannot be disassembled.




d.

Install the clutch tube boot to the manual transaxle assembly.


e.
C274621

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


f.

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


g.
C197021

Using a 10 mm union nut wrench, install the bleeder clutch release tube to the clutch release with bearing cylinder assembly.

Torque:
15.2 N*m (155 kgf*cm, 11 ft.*lbf)

NOTICE:
·

Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

·

Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a union nut wrench.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION




h.
C196061C01
1.198,1.177 1.188,1.167 false
V100135

Clutch Spline Grease


Apply clutch spline grease to the input shaft splines.

Grease:

Toyota Genuine Clutch Spline Grease or equivalent



Hide 31407B 5.REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

a.
C274621

Disconnect the bleeder clutch release tube from the clutch release bleeder sub-assembly.


b.

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


Hide 6.INSPECT CLUTCH PIPE LINE

C298551N01
2.646,1.698 2.646,1.458 false 2.51,1.708 2.969,1.906 0.458,0.198 10 false SST

a.

Using SST, apply 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 bleeder clutch release tube.


Hide 31407B 7.INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

a.
C274621

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


b.

Install the 2 bolts and clutch release bleeder sub-assembly to the manual transaxle assembly.

Torque:
16.7 N*m (170 kgf*cm, 12 ft.*lbf)


c.

Using a 10 mm union nut wrench, connect the bleeder clutch release tube to the clutch release bleeder sub-assembly.

Torque:
15.2 N*m (155 kgf*cm, 11 ft.*lbf)

NOTICE:
·

Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

·

Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a union nut wrench.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION




Hide 31482 8.INSTALL CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE

a.

Using a 10 mm union nut wrench, install the clutch release cylinder to flexible hose tube to the clutch release bleeder sub-assembly.

Torque:
15.2 N*m (155 kgf*cm, 11 ft.*lbf)

NOTICE:
·

Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

·

Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a union nut wrench.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION




b.

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

Torque:
8.0 N*m (82 kgf*cm, 71 in.*lbf)