CAUTION / NOTICE / HINT
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
INSTALL CLUTCH DISC ASSEMBLY
*1 | Clutch Disc Assembly |
*a | Flywheel Sub-assembly Side |
Insert SST into the clutch disc assembly, then insert them both into the flywheel sub-assembly.
Insert the clutch disc assembly in the correct direction.
INSTALL CLUTCH COVER ASSEMBLY
*a | Temporarily |
*b | Matchmark |
Align the matchmark on the clutch cover assembly with the one on the flywheel sub-assembly.
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.
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.
INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.
Maximum Non-alignment |
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0.5 mm (0.0197 in.) |
If the alignment is not as specified, using SST, adjust the diaphragm spring tip alignment.
INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY
Temporarily tighten the clutch release cylinder to bleeder tube to a new clutch release with bearing cylinder assembly.
Clean and degrease all installation surfaces for the clutch release with bearing cylinder assembly.
Install the clutch release with bearing cylinder assembly with 3 new bolts.
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 holding the clutch release with bearing cylinder assembly.
Ensure that none of the clutch disc spline grease adheres to the clutch release with bearing cylinder assembly.
The clutch release with bearing cylinder assembly cannot be disassembled.
Install the clutch tube boot onto the manual transaxle assembly.
Temporarily tighten the clutch release cylinder to bleeder tube to the clutch release bleeder sub-assembly.
Temporarily tighten the 2 bolts and install the clutch release bleeder sub-assembly.
Using a 10 mm union nut wrench, install the clutch release cylinder to bleeder tube to the clutch release with bearing cylinder assembly.
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.
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Apply clutch spline grease to the input shaft splines.
Clutch spline grease |
Sealant |
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Toyota Genuine Clutch Spline Grease or equivalent |
REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY
Separate the clutch release cylinder to bleeder tube from the clutch release bleeder sub-assembly.
Remove the 2 bolts and clutch release bleeder sub-assembly.
INSPECT CLUTCH PIPE LINE
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.
If the pressure drops, replace the clutch release cylinder to bleeder tube.
INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY
Temporarily tighten the clutch release cylinder to bleeder tube to the clutch release bleeder sub-assembly.
Install the 2 bolts and clutch release bleeder sub-assembly.
Using a 10 mm union nut wrench, install the clutch release cylinder to bleeder tube.
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.
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INSTALL ACCUMULATOR TO FLEXIBLE HOSE TUBE
Using a 10 mm union nut wrench, install the accumulator to flexible hose tube to the clutch accumulator assembly and clutch release bleeder sub-assembly.
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.
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Install the bolt and accumulator to flexible hose tube to the manual transaxle assembly.
INSTALL MANUAL TRANSAXLE ASSEMBLY
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