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, and then insert them both into the flywheel sub-assembly.
SST : 09301-00210
Text in Illustration
NOTICE:
Insert the clutch disc assembly so that it faces 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.
Text in Illustration
(b) Install the clutch cover assembly and temporarily install the bolt labeled 1.
(c) 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.
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, and right and left lightly after checking that the disc is in the center, and then tighten the bolts.
(d) Remove SST.
3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
(a) Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.
Maximum misalignment:
0.5 mm (0.0196 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) Connect the bleeder clutch release tube to a new clutch release with bearing cylinder assembly and temporarily tighten the union nut.
(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.
* Make sure 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 to the transaxle case.
(e) Temporarily connect the clutch release bleeder sub-assembly to the bleeder clutch release tube.
(f) Temporarily install the clutch release bleeder sub-assembly to the transaxle case with the 2 bolts.
(g) Using a union nut wrench, tighten the union nut of the bleeder clutch release tube to connect it to the clutch release with bearing cylinder assembly.
Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)
NOTICE:
Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Service Precautions.
(h) Apply clutch spline grease to the input shaft splines.
Text in Illustration
Grease:
Toyota Genuine Clutch Spline Grease or equivalent
5. INSPECT CLUTCH PIPE LINE
(a) Disconnect the clutch release bleeder sub-assembly from the bleeder clutch release tube.
(b) Remove the 2 bolts and clutch release bleeder sub-assembly.
(c) 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 bleeder clutch release tube.
6. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY
(a) Temporarily connect the clutch release bleeder sub-assembly to the bleeder clutch release tube.
(b) Install the clutch release bleeder sub-assembly with the 2 bolts.
Torque : 17 Nm (170 kgf-cm, 12 ft-lbf)
(c) Using a union nut wrench, tighten the union nut of the bleeder clutch release tube.
Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)
NOTICE:
Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Service Precautions.
7. INSTALL BLEEDER TO ACCUMULATOR TUBE
(a) Temporarily install the bleeder to accumulator tube.
(b) Using a union nut wrench, tighten the 2 unions of the bleeder to accumulator tube.
Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)
NOTICE:
Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Service Precautions.
(c) Connect the clutch line clamp to the transaxle with the bolt.
Torque : 12 Nm (120 kgf-cm, 9 ft-lbf)
8. INSTALL MANUAL TRANSAXLE ASSEMBLY
Installation